4 Stroke
90/115/140 HORSEPOWER
PL4, PX4, X4, CX4
*5035765* ! WARNING
WARNING
Be careful! Human error is caused by many factors: carelessness, fatigue, overload, preoccu-
pation, unfamiliarity of operator with the product, drugs and alcohol to name a few. Damage to
your boat and outboard can be fixed in a short period of time, but injury or death, has a lasting
effect.
For your safety and the safety of others, read this Guide from cover to cover and follow all
safety warnings and recommendations. Do not disregard any of the safety precautions and
instructions.
Anyone operating your boat should first read and understand this Guide before they operate
your boat and motor.
The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates:
Evinrude® Johnson®
Evinrude®/Johnson® Genuine Parts Hi-Vis™ gearcase lubricant
Evinrude®/Johnson® 4-Stroke outboard oil S.L.O.W.™
Evinrude®/Johnson® Ultra™ 4-Stroke synthetic blend oil SystemCheck™
Evinrude®/Johnson® anti-corrosion spray Triple-Guard® grease
2+4® fuel conditioner Ultra-HPF™ gearcase lubricant
99011-90J04-BBD
0-
Contents
GENERAL INFORMATION ................................................................................................... 2
SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2
PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4
BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON
4-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ..................................... 5
BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON
4-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ......................... 8
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 9
FEATURES ............................................................................................................................................................... 12
ENGINE SPECIFICATIONS ...................................................................................................................................... 14
ENGINE SPECIFICATIONS ...................................................................................................................................... 15
REMOTE CONTROL ................................................................................................................................................. 16
ENGINE MONITORING ...................................................................................................... 18
FUEL AND OIL ................................................................................................................... 19
FUEL ......................................................................................................................................................................... 19
OIL ............................................................................................................................................................................. 20
ADDITIVES ................................................................................................................................................................ 20
FUEL SYSTEM .......................................................................................................................................................... 20
BREAK-IN (10 HOURS) ............................................................................................................................................ 21
ENGINE STARTING ........................................................................................................... 22
BEFORE START-UP ................................................................................................................................................. 22
ENGINE STOPPING ................................................................................................................................................. 23
SHIFTING AND SPEED CONTROL ......................................................................................................................... 24
FUEL ECONOMY ...................................................................................................................................................... 25
OPERATION ....................................................................................................................... 26
POWER TRIM AND TILT .......................................................................................................................................... 26
PROPELLER SELECTION ....................................................................................................................................... 29
MOORING ................................................................................................................................................................. 29
FLUSHING ................................................................................................................................................................ 29
ENGINE OVERHEATING .......................................................................................................................................... 31
TRAILERING ............................................................................................................................................................. 32
TILT SUPPORT ......................................................................................................................................................... 32
IMPACT DAMAGE .................................................................................................................................................... 33
STORING .................................................................................................................................................................. 33
SPECIAL OPERATING CONDITIONS ..................................................................................................................... 34
MAINTENANCE .................................................................................................................. 35
ENGINE EMISSIONS INFORMATION ...................................................................................................................... 35
10-HOUR INSPECTION ............................................................................................................................................ 36
OFF-SEASON STORAGE ........................................................................................................................................ 36
PRE-SEASON SERVICE .......................................................................................................................................... 38
BATTERY .................................................................................................................................................................. 39
CRANKCASE OIL AND FILTER .............................................................................................................................. 40
ADJUSTMENTS ........................................................................................................................................................ 41
LUBRICATION .......................................................................................................................................................... 42
WATER PRESSURE ................................................................................................................................................. 44
FUEL LINE FILTER ................................................................................................................................................... 44
FUSES ....................................................................................................................................................................... 44
SPARK PLUGS ......................................................................................................................................................... 45
PROPELLER ............................................................................................................................................................. 45
ANTICORROSION ANODES .................................................................................................................................... 46
BONDING WIRES ..................................................................................................................................................... 47
MOTOR REMOVAL AND TRANSPORTING ............................................................................................................ 47
TROUBLE CHECK CHART ...................................................................................................................................... 48
ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 50
SAFETY — THE RIGHT PLACE TO GET A responsible, educated boater will fully appreciate
the pleasures of boating and will be a safe boater.
STARTED Boating Safety Classes are conducted by the U.S.
Coast Guard Auxiliary, the U.S. Power Squadron
This Operator’s Guide contains essential informa- and some Red Cross Chapters. For information
tion to help prevent personal injury and damage to about classes, call toll free 1-800-336-BOAT. For
equipment. It will acquaint the operator and pas- additional information about boating safety and reg-
sengers with the Evinrude/Johnson outboard and ulations call: U.S. Coast Guard Boating Safety Hot-
its controls, operation, maintenance and boating line 1-800-368-5647. Outside North America
safety measures. Make sure all operators read, un- please contact your Dealer or distributor for details
derstand and follow the contents. This Guide about boating safety.
should be kept in a waterproof bag with the product
at all times during operation. If the product owner-
ship is transferred, this Guide should be forwarded SAFETY MEASURES — General
to the subsequent owners. To fully appreciate the pleasures, enjoyment
This Operator’s Guide uses the following signal and excitement of boating there are some ba-
words identifying important safety messages. sic rules that should be observed and fol-
These safety alert signal words mean: lowed by any boater. Some rules may be new
ATTENTION! to you and others may be common sense or
BECOME ALERT! obvious... irrespective, take them seriously!
YOUR SAFETY IS INVOLVED! Failure to follow this safety information and
safe boating rules could result in injury to you,
your passengers or other water users.
DANGER
Become completely familiar with the control
Indicates an imminently hazardous situa- and operation of your boat and motor before
tion which, if not avoided, WILL result in embarking on your first trip or taking on a pas-
death or serious injury. senger(s). If you have not had the opportunity
to do so with your Dealer, practice driving in
a suitable area and feel the response of each
control. Be familiar with all controls before ap-
plying the throttle above idle speed. As the
WARNING operator, you are in control and responsible
for safe operation.
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe SAFETY MEASURES — Operation
injury or death.
Be sure at least one of your passengers
knows how to handle your boat in case of an
emergency.
CAUTION All passengers should know the location of
emergency equipment and how to use it.
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or All safety equipment and personal flotation
moderate personal injury or property dam- devices must be in good condition and suit-
age. It also may be used to alert against able for your type of boat. Always comply with
unsafe practices. the regulations that apply to your boat.
2 - General Information
Whenever running the engine, assure there Do not operate your boat if you are under the
is proper ventilation to avoid carbon monox- influence of drugs or alcohol.
ide (CO), which is odorless, colorless, and
tasteless, and can lead to unconsciousness, High performance boats have a high power-
brain damage, or death if inhaled in sufficient to-weight ratio. If you are not experienced in
concentrations. CO accumulation can occur the operation of a high performance boat, do
while docked, anchored, or underway, and in not attempt to operate one at, or near, its top
many confined areas such as the boat cabin, speed until you have gained that experience.
cockpit, swim platform, and heads. It can be
worsened or caused by weather, mooring For more information, see your Evinrude/
and operating conditions, and other boats. Johnson Dealer for a copy of Introduction to
Avoid exhaust fumes from your engine or oth- High Performance Boating, P/N 335763.
er boats, provide proper ventilation, shut off
your engine when not needed, and be aware
of the risk of backdrafting and conditions that SAFETY MEASURES — Installation and
create CO accumulation. In high concentra- Maintenance
tions, CO can be fatal within minutes. Lower
concentrations are just as lethal over long pe- Outboard Installation
riods of time.
The outboard must be correctly installed.
Proceed with caution and at very low speed Failure to correctly install the outboard could
in shallow water. Grounding or abrupt stops result in serious injury, death or property
may result in injury. Also be alert for debris damage. We strongly recommend that your
and objects in the water. Dealer install your outboard to ensure proper
installation.
Be familiar with the waters you are operating
in. The gearcase of this outboard extends be- Do not overpower your boat by using an en-
low the water surface and could potentially gine that exceeds the horsepower indicated
come in contact with underwater obstruc- on the boat’s capacity plate. Overpowering
tions. Contact with underwater obstructions could result in loss of control. If your boat has
may result in loss of control and personal in- no capacity plate, contact your Dealer or the
jury. boat’s manufacturer.
General Information - 3
PRODUCT REFERENCES, Model and Serial Numbers
ILLUSTRATIONS AND The model and serial numbers appear on a plate at-
SPECIFICATIONS tached to the stern bracket or swivel bracket.
Record your outboard’s:
4 - General Information
BOMBARDIER MOTOR CORPORATION OF AMERICA
LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD IN THE UNITED STATES AND CANADA
TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related components
providing input to emission controls (e.g. sensors) are warranted for twenty-four (24) months or two hun-
dred (200) hours of engine use, whichever occurs first. The Product is used commercially when it is used
in connection with any work or employment that generates income, during any part of the warranty period.
The Product is also used commercially when, at any point during the warranty period, it is installed on a
boat that has commercial tags or is licensed for commercial use.
The repair or replacement of parts or the performance of service to Product under this warranty does not
extend the life of this limited warranty beyond its original expiration date. All Evinrude/Johnson Genuine
Parts and accessories installed by an authorized dealer at the time of sale, including but not limited to pro-
pellers, bear the standard BMCA parts and accessories one-year limited warranty.
California residents who purchased or warranty-registered a Product in California should refer to BMCA's
California Emissions Control Warranty Statement.
Only the original purchaser and any subsequent owners who reside in the United States and Canada and
have purchased Product from a U.S. or Canadian Dealer are eligible for warranty registration and warran-
ty coverage hereunder. Such limitations are necessary in order to allow BMCA to protect the safety of its
products, its consumers, and the general public.
As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintain
warranty coverage. BMCA may require proof of proper maintenance prior to authorizing warranty cover-
age.
General Information - 5
4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE
The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect.
Owner must bring Product, including any defective part therein, to Dealer promptly after the appearance
of the defect, and in any event, within the warranty period, and must provide Dealer with reasonable op-
portunity to repair the defect. The expenses of transporting Product to and from Dealer for warranty ser-
vice are to be borne by the owner.
If the Product has not previously been registered, the owner may also be required to present proof of pur-
chase to Dealer for warranty repairs. Owner is required to sign the repair/work order prior to the start of
the repair in order to validate the warranty repair.
All parts replaced under this warranty become the property of BMCA.
In the event that warranty service is required outside of the fifty United States or Canada, owner will bear
responsibility for any additional charges due to local practices and conditions, such as, but not limited to,
freight, insurance, taxes, license fees, import duties, and any and all other financial charges, including
those levied by governments, states, territories and their respective agencies.
BMCA reserves the right to improve, modify or change Products from time to time without assuming any
obligation to modify Products previously manufactured.
This warranty will be voided in its entirety and rendered null and void where:
• Product has been altered or modified in such a way so as to adversely affect its operation, performance
or durability, or change its intended use, horsepower or emission levels; or
• Product is or has been used for racing at any point, even by a prior owner.
6 - General Information
7. LIMITATIONS OF LIABILITY
ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN-
TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA-
TION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY.
SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIM-
ITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTI-
FIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM
STATE TO STATE, OR PROVINCE TO PROVINCE.
No distributor, Dealer or any other person is authorized to make any affirmation, representation or war-
ranty regarding Product other than those contained in this limited warranty and, if made, shall not be en-
forceable against BMCA. BMCA reserves the right to modify this warranty at any time, being understood
that such modification will not alter the warranty conditions applicable to the Products sold while this war-
ranty is in effect.
8. TRANSFER
If the ownership of Product is transferred during the warranty coverage period, this warranty shall also be
transferred and be valid for the remaining coverage period provided that the former or new owner promptly
contacts BMCA or Dealer and gives the name and address of the new owner.
9. CONSUMER ASSISTANCE
• In the event of a controversy or dispute in connection with this BMCA limited warranty, BMCA recom-
mends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer's
service manager or owner;
• If further assistance is required, please contact the Bombardier Motor Corporation of America Customer
Support Services, 250 Sea Horse Drive, Waukegan, IL, 60085, 1-847-689-7090.
General Information - 7
BOMBARDIER MOTOR CORPORATION OF AMERICA
LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD OUTSIDE THE UNITED STATES AND CANADA
For a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distrib-
utor/dealer authorized to distribute Johnson 4-Stroke products in the country in which the sale occurs.
If further assistance is required, please contact Bombardier Motor Corporation of America Customer Sup-
port Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BMCA where the Product
was registered for warranty.
8 - General Information
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
Your Johnson 4-stroke outboard has a special environmental label required by the California Air Resourc-
es Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard, describes
the meaning of the star rating system.
The Star Label means Cleaner Marine Engines
General Information - 9
Manufacturer's Limited Warranty Coverage
This emission limited warranty covers Johnson 4-stroke outboards certified and produced by BMCA for
sale in California, that are originally sold in California to a California resident, or subsequently warranty-
registered to a California resident. The BMCA U.S. and Canada limited warranty conditions for Johnson
4-stroke outboards are still applicable to these models with the necessary modifications.
Select emission control parts of your Johnson 4-stroke outboard are warranted from the date of purchase
by the first retail consumer or the date the product is first put to use, whichever occurs first, for a period
of: 4 years, or for 250 hours of use, whichever occurs first.
However, warranty coverage based on the hourly period is only permitted for outboards equipped with the
appropriate hour meters or their equivalent. If any emission-related part on your engine is defective under
warranty, the part will be repaired or replaced by BMCA.
Parts covered are:
10 - General Information
The emission warranty covers damage to other engine components that is caused by the failure of a war-
ranted part.
The BMCA Operator's Guide provided contains written instructions for the proper maintenance and use
of your outboard. All emission warranty parts are warranted by BMCA for the entire warranty period of the
outboard, unless the part is scheduled for replacement as required maintenance in the Operator's Guide.
Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by
BMCA for the period of time before the first scheduled replacement date for that part. Emission warranty
parts that are scheduled for regular inspection but not regular replacement are warranted by BMCA for
the entire warranty period of the outboard. Any emission warranty part repaired or replaced under the
terms of this warranty statement is warranted by BMCA for the remainder of the warranty period of the
original part. All parts replaced under this limited warranty become the property of BMCA.
Maintenance receipts and records should be transferred to each subsequent owner of the outboard.
Owner's Warranty Responsibilities
As the outboard owner, you are responsible for the performance of the required maintenance listed in your
Operator's Guide. BMCA recommends that you retain all receipts covering maintenance on your out-
board, but BMCA cannot deny warranty solely for the lack of receipts or your failure to ensure the perfor-
mance of all scheduled maintenance.
As the outboard owner, you should however be aware that BMCA may deny you warranty coverage if your
outboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
You are responsible for presenting your outboard to an authorized BMCA dealer as soon as a problem
exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.
For any questions regarding your warranty rights and responsibilities or for the name and location of the
nearest authorized BMCA dealer, contact Bombardier Motor Corporation of America Customer Support
Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.johnson.com.
General Information - 11
FEATURES
10
9
11
8
1
2 7
6 12
3
4
5
000256
12 - General Information
16
20
13 14
19 17
15
18
000257
General Information - 13
ENGINE SPECIFICATIONS
(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.
(2) Emission Control Information.
(3) Not supplied in all marketing areas.
14 - General Information
ENGINE SPECIFICATIONS
140 Models
Displacement 124.7 cu. in. (2044 cm3)
Engine Type Four-Cycle, In-line, 4 Cylinder
Electronic Fuel Injection
Full Throttle Operating Range 5600 to 6200 RPM
Power (1) 140 HP (103.0 kw) @ 5900 RPM
Idle RPM in Gear (2) 700 ± 25
Ignition Timing – Idle (2) Not Adjustable
W.O.T. Not Adjustable
Exhaust Emission Control System: SFI
per SAE J1930 (2)
Fuel Requirements (2) 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil
Crankcase – Oil Evinrude/Johnson Ultra 4-Stroke Synthetic Blend Oil
Capacity 5.8 qts. (5.5 liters)
Warning Signals Engine Overheat and Low Oil Pressure
Ignition Features S.L.O.W.™ (Speed Limiting Overheat Warning)
Starting Remote electric
Battery, Minimum (3) 12-Volt, 512 CCA (620 MCA) with 160 minutes reserve capacity
OR 100 ampere-hour
Spark Plug (2) Refer to ECI Label
Torque 18 to 21 ft. lbs. (24 to 28 N·m)
Fuse Refer to Fuses
Fuel Line Filter P/N 5033704
Alternator 17-Amp, Fully Regulated
Gearcase – Lubricant Evinrude/Johnson Ultra-HPF gearcase lubricant
Capacity 35.5 fl. oz. (1050 ml)
Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)
Propeller (3) See your Dealer
Weight L - 410 lbs. (186 kg)
X - 421 lbs. (191 kg)
Sound at Driver’s Ear 86.6 dB(A)
(LpA) ICOMIA 39.94
Transom Height L - 19 1/2 to 20 in. (49.5 to 50.8 cm)
X - 24 1/2 to 25 in. (62.2 to 63.5 cm)
(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.
(2) Emission Control Information.
(3) Not supplied in all marketing areas.
General Information - 15
REMOTE CONTROL
WARNING
If you choose a non-Evinrude/Johnson
remote control, be sure it has a start-in-gear
prevention feature. This feature can prevent
injuries resulting from unexpected boat
movement when the engine starts.
5
Evinrude/Johnson side mount control
1. Handle – shift and throttle
2. Trim/tilt switch (where equipped)
Evinrude/Johnson concealed side mount control 3. Neutral lock tab
4. Fast idle lever
1. Handle – shift and throttle
5. Emergency stop clip and lanyard
2. Trim/tilt switch (where equipped)
6. Throttle friction control
3. Neutral lock tab
4. Fast idle button
5. Throttle friction control
16 - General Information
Emergency Stop/Key Switch
A combination emergency stop switch and key WARNING
switch is a feature of Evinrude/Johnson prewired
remote controls and all Evinrude/Johnson control Avoid knocking or pulling the clip off the
wiring kits. Use of the emergency stop feature is stop switch during normal boating. Avoid
highly recommended on all boats. bumping the key if operating without the
Connect the clip to the emergency stop/key switch. clip on the switch. The resulting unexpected
Snap the lanyard to a secure place on the opera- loss of forward motion can throw occupants
tor’s clothing or life vest — not where it might tear forward, causing injury.
away instead of activating the stop switch. Discon-
necting the clip and lanyard will stop the engine and Your emergency stop switch can be effec-
prevent the boat from becoming a runaway if the tive only when in good working condition.
driver moves beyond the range of the lanyard. If the At each outing, inspect clip and lanyard for
lanyard is too long, it can be shortened by knotting cuts, breaks, or wear. Replace worn or dam-
or looping it. DO NOT cut and retie the lanyard. In aged parts.
an emergency situation, the engine can be started Keep the lanyard free from obstructions and
without the clip in place. Follow the normal starting entanglements.
procedure. Reinstall a clip as soon as possible.
At each outing, test the system’s operation.
With the engine running, remove the clip
from the switch by pulling the lanyard. If the
engine does not stop running, see your
Dealer.
1. Clip
2. Emergency stop / key switch
3. Lanyard
General Information - 17
ENGINE MONITORING
IMPORTANT: Your outboard must be equipped
with the SystemCheck™ (or equivalent) engine
monitor. Operating your outboard without the Sys-
temCheck (or equivalent) engine monitor will void
your warranty for failures related to the functions
monitored on your engine.
When you turn the key switch ON, the System-
Check engine monitor horn performs a self-test by
sounding a 1/2-second beep. The gauge self-tests
by turning the warning lights on, then off in se-
quence. During engine start-up, pause with the key
switch in the ON position to observe the horn and
gauge perform the self-test. If the self-test does not
happen as stated, see your Dealer.
The SystemCheck engine monitor alerts the opera-
1 2
tor with a 10-second beep of the horn and a warning 1. SystemCheck Gauge
light on the gauge when certain engine problems 2. SystemCheck Gauge with Tachometer
occur. The appropriate warning light will stay on
until the key switch is turned OFF.
"NO OIL"
If the engine management module (EMM) senses
that the problem could cause permanent engine The engine’s oil pressure is too low to continue nor-
damage, it will also limit engine speed to 3000 mal operation. Serious engine damage can occur
RPM. This additional protection feature is referred quickly. The EMM will limit the engine speed to
to as S.L.O.W.™ If the engine was running faster 3000 RPM.
than 3000 RPM when the S.L.O.W. system activat- Causes of low oil pressure can include:
ed, it will shake noticeably.
• Insufficient oil in the crankcase.
• Air in the system causing oil to foam.
CAUTION • Malfunction of oil delivery components.
• Blockage of oil system components.
In the S.L.O.W. mode, the engine speed is
limited. Under certain conditions, the To RESET the S.L.O.W. protection system – Oil
engine’s limited speed may reduce maneu- pressure must be restored and engine slowed to
verability of your boat. 3000 RPM.
Return to harbor if you cannot restore adequate oil
If the S.L.O.W. mode is activated and you pressure. For more information about evaluating
are unable to correct the problem, seek low oil pressure, refer to Low Oil Pressure Warn-
assistance and/or return to safe harbor. ing.
Serious engine damage, engine shutoff,
and/or reduced maneuverability may be
imminent. "WATER TEMP" or HOT
The engine is overheating. Serious engine damage
can occur quickly.
If the engine is overheating, it will also activate
S.L.O.W. and limit engine speed to 3000 RPM.
IMPORTANT: Refer immediately to Engine Over-
heating.
18 - Engine Monitoring
FUEL AND OIL
WARNING
The engine cover is a machinery guard. DO
NOT operate your outboard with the cover 1. Fuel hose to fuel connector
off unless you are performing maintenance,
and then be careful to keep hands, hair, and If the fuel tank has an operable vent, open it.
clothing clear of all moving parts. Contact Squeeze the fuel primer bulb, outlet end up, until
with moving parts could cause injury. firm.
WARNING
Contact with a rotating propeller is likely to
result in serious injury or death. Assure the
engine and prop area is clear of people and
objects before starting engine or operating
boat. Do not allow anyone near a propeller,
even when the engine is off. Blades can be
sharp and the propeller can continue to turn
even after the engine is off. Always shut off
the engine when near people in the water.
1. Clip
2. Emergency stop / key switch
3. Lanyard
22 - Engine Starting
IMPORTANT: The engine will start and run without After Engine Starts
the clip connected to the key switch. However, we
strongly recommend that the operator use the clip DO NOT turn the key switch to START while the en-
and lanyard anytime the engine is running. Refer to gine is running. Damage to the starter system could
Emergency Stop/Key Switch. result.
Move the remote control handle to NEUTRAL. Re- Allow the engine to idle in NEUTRAL for about 5
fer to Shifting and Speed Control. minutes to warm up before shifting.
IMPORTANT: To avoid engine damage after start-
up do not exceed 2000 RPM in NEUTRAL. Do not
exceed 1500 RPM in NEUTRAL for extended peri-
ods of time.
Check the water pump indicator. A steady stream of
1 water indicates the water pump is working. If a
steady stream of water from the water pump indica-
tor is not visible, stop the engine. Refer to Engine
Overheating.
1. NEUTRAL
Start-up
Turn the key switch fully clockwise to the START
position. Crank the engine no longer than 10 sec-
onds.
1
ENGINE STOPPING
Engine Starting - 23
SHIFTING AND SPEED CONTROL Binnacle Mount Control
Briskly and decisively, move the control handle fore
IMPORTANT: Carefully check the function of all or aft — until it engages the gear detent.
control and engine systems before leaving the
dock. DO NOT shift the engine into FORWARD or
REVERSE while it is shut OFF. If the following di-
rections are not suitable for your boat’s control, see
your Dealer before proceeding.
Shifting
With engine running and control handle in NEU-
TRAL:
Speed Control
2 After gear engagement, move the control handle
slowly in the same direction to increase speed.
24 - Engine Starting
Fast Idle in NEUTRAL FUEL ECONOMY
Concealed Side Mount and Binnacle Mount Con- The economy throttle range can save fuel, depend-
trols ing on boat load and hull design. When boat reach-
es top speed, throttle back from FULL SPEED to
IMPORTANT: Avoid excessive engine RPM in the economy throttle range. You will save fuel with-
NEUTRAL — adjust the throttle so the engine does
out a noticeable loss of speed.
not overspeed.
With the control handle in NEUTRAL, push the fast
idle button while using the other hand to move the
control handle forward, past the forward gear de-
tent and into the throttle range. If equipped with a
neutral lock tab, squeeze it to begin handle travel.
Engine Starting - 25
OPERATION
The power tilt is often used to tilt the engine for
clearance when beaching, mooring, or launching.
DANGER
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust WARNING
fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide Disconnect the fuel line whenever you leave
which, if inhaled, can cause serious brain the motor tilted up for a long period of time,
damage or death. or fuel may leak out.
WARNING
Contact with a rotating propeller is likely to
result in serious injury or death. Assure the
engine and prop area is clear of people and
objects before starting engine or operating
boat. Do not allow anyone near a propeller,
even when the engine is off. Blades can be
sharp and the propeller can continue to turn
even after the engine is off. Always shut off
the engine when near people in the water.
26 - Operation
Manual Release Tilting
To operate the power tilt, push and hold the trim/tilt
switch in the bow-up or bow-down position. The en-
WARNING gine will tilt up or down until the switch is released
or the engine reaches the end of its travel.
Keep everyone clear of a tilted engine when
backing out the manual release screw. The
engine could drop suddenly and forcibly. Be
sure to tighten the manual release screw
after manually repositioning the engine.
Tightening the screw also reactivates the
engine’s shock absorber protection and
reverse thrust capability.
Trimming
To operate the power trim, push and hold the trim/
tilt switch in the desired bow direction, either bow-
up or bow-down. The engine will move until the
switch is released or the engine reaches its maxi-
mum position.
1
The boat will be properly trimmed when the trim an-
gle provides a bow position that results in the best
boat performance for your operating conditions.
You must use a speedometer and tachometer to
determine boat and engine performance at different
trim positions. To help maintain steering stability
1. Manual release screw and good performance, always maintain the proper
trim angle, which varies depending on the combina-
tion of boat, motor, propeller, and operating condi-
tions.
To familiarize yourself with power trim, make test
runs with the boat’s bow at various positions. Note
the time it takes for the boat to plane, the tachome-
ter and speedometer readings, and the ride and ac-
tion of the boat.
Operation - 27
Bow-Up Bow-Down
BOW-UP position will give the best fuel economy BOW-DOWN position will give the best accelera-
and highest top speed. tion onto plane and the best towing power for skiing.
The bow-down position is normally used for accel-
Operating Conditions:
erating from a standing start or from idle speed.
In the bow-up position, your boat may tend to pull to Operating Conditions:
the left. If this condition exists, correct it by applying
a clockwise force with the steering wheel to keep on In the bow-down position, your boat may tend to
a straight path. The trim tab can also be adjusted to pull to the right. If this condition exists, correct it by
compensate for steering wheel torque, but adjust applying a counterclockwise force with the steering
the trim tab only if bow-up is commonly used. Refer wheel to keep on a straight path. The trim tab can
to Trim Tab. also be adjusted to compensate for this steering
When the motor is trimmed to full bow-up position, wheel torque, but adjust the trim tab only if bow-
the boat’s bow will tend to rise above the water. down is commonly used. Refer to Trim Tab.
Excessive bow-up trim may cause propeller ventila- When the motor is trimmed to full bow-down posi-
tion, resulting in propeller slippage. tion, the boat’s bow will tend to go deeper into the
water (plow).
IMPORTANT: Some boats plow, or are difficult to
WARNING plane, when operated in the trim’s lowest position.
If your boat handles unsuitably when trimmed fully
When operating in rough water or crossing bow-down, set the angle adjusting rod or trim limiter
a wake, excessive bow-up trim may result in rod to limit the travel of the power trim. If your motor
the boat’s bow suddenly rising skyward, is not equipped with this rod, purchase one from
possibly ejecting occupants. your Dealer.
WARNING
WARNING If the bow of the boat plows the water at
high speeds, the boat may bow steer or spin
Some boat/motor/propeller combinations suddenly, possibly ejecting occupants.
may encounter boat instability and/or high
steering torque when operated at high
speed at or near the motor’s trim range lim-
its (full bow-up or bow-down). Boat stability
and steering torque can also vary due to
changing water conditions. If any adverse
conditions occur, reduce throttle and/or
adjust trim angle to maintain control. If you
experience boat instability and/or high
steering torque, see your Dealer to correct
these conditions.
28 - Operation
PROPELLER SELECTION MOORING
To select the correct propeller for your boating ap- You may moor your boat with the motor’s gearcase
plication, your boat and motor MUST be water test- out of the water by using its tilt feature. Depending
ed. See your Dealer for assistance. on the model, refer to Tilt Support or Power Trim
Refer to Propeller, before removing or installing and Tilt.
propeller.
IMPORTANT: The correct propeller for your boat, FLUSHING
under normal load conditions, will allow the engine
to run near the midpoint of the RPM operating
range at full throttle. Refer to Engine Specifica-
tions. DANGER
Right-hand propellers are considered standard ro-
tation propellers. When propelling a boat forward, DO NOT run the engine indoors or without
the propeller rotates in a right-hand (clockwise) di- adequate ventilation or permit exhaust
rection as viewed from the rear. fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide
Left-hand propellers are considered counter-rota- which, if inhaled, can cause serious brain
tion propellers. When propelling a boat forward, the damage or death.
propeller rotates in a left-hand (counterclockwise)
direction as viewed from the rear.
See your Dealer for a flushing device designed to fit
your engine. Follow manufacturer’s instructions for
installing and using it.
Outboard — Running
WARNING
Prevent injury from contact with rotating
propeller; remove the propeller before
flushing.
WARNING
If you have a dual engine installation that
includes a counter-rotating engine and you
remove the propellers, always check to be
sure they are installed on the correct
engines before aggressively operating your
boat. Shift each motor individually into
FORWARD or REVERSE, at idle speed only.
If the boat moves opposite the direction
indicated by the remote control handle, the
wrong propeller has been installed on the
motor being checked. Install the correct
propeller and confirm your installation
using the above method before any attempt
is made to operate the boat.
Operation - 29
3) Place the remote control lever in NEUTRAL 4) If needed, use a hose connector matched to
with the propeller removed. the flushing port thread. The flushing port
4) Start the water — keep pressure between 20 thread is 0.75 – 11.5 NHR (ANSI). A suitable
to 40 psi (140 to 300 kPa). connector is commercially available at most
5) Start the engine — run it at idle only and hardware outlets.
flush it for at least five minutes. Check the
water pump indicator. A steady stream of wa-
ter must flow. If it does not, shut OFF the en-
gine and investigate. Refer to Engine 1
Overheating.
6) Shut OFF the engine and remove the flusher.
7) Leave the outboard in vertical position long
enough to completely drain the powerhead.
1. Flushing port
2. Garden hose
30 - Operation
ENGINE OVERHEATING IF cleaning the screens and indicator does not re-
store the water pump indicator’s steady discharge,
SHUT OFF the engine and do not attempt to oper-
IMPORTANT: Do not run your engine — even for a ate it. See your Dealer.
brief start-up — without supplying water to it. Refer
to Flushing. IF cleaning the screens and indicator does restore
the water pump indicator’s steady discharge, you
While boating, the engine’s water intakes must stay might have to run for two minutes in NEUTRAL to
completely submerged and unobstructed. Observe allow the engine to cool and the light to go off.
proper transom height and trim angle. If the warning light stays on after two minutes,
While the engine is running, the engine’s water STOP the engine and see your Dealer.
pump indicator must discharge a steady stream of
water. Check the indicator often, especially when IMPORTANT: You must restore cooling to the en-
operating in weeds, muddy and debris-laden water, gine to avoid serious engine damage.
and at extreme trim angles. After any overheat, have your Dealer:
Torque the exhaust manifold bolts and zinc anode
cover and the cylinder head screws.
Inspect the water pump for excessive wear or dam-
age.
Inspect the water pipe and its O-ring.
Inspect the condition and sealing of the exhaust
manifold gasket.
Inspect the thermostats.
Inspect the engine for leaks.
Inspect water pressure valve.
Check engine oil level.
Operation - 31
TRAILERING Engage the tilt support lever if you intend to leave
the motor tilted for a period of time:
• Tilt the motor UP using the trailering tilt switch.
• Flip the tilt support lever down.
WARNING
Keep everyone clear of stern area when
raising or lowering the outboard. Personal
injury or death can result from contact with
moving parts of the outboard. 1
WARNING
Always use the power tilt to lift and support
the motor BEFORE you disengage the tilt
support lever. If oil pressure is lost while
using the tilt support lever, the motor can
drop suddenly when the support is disen-
gaged. If the power tilt will not lift the motor,
do not attempt to force the tilt lever from its
position on the stern brackets. See your
Dealer.
32 - Operation
IMPACT DAMAGE If you hit any object, stop immediately and examine
the engine for loosening of attaching hardware and
clamp screws, if equipped. Inspect for damage to
Your engine has a shock absorption system de- swivel and stern brackets, steering components,
signed to help withstand damage from impact with and components in the area of impact. Also, exam-
underwater objects at low to moderate speeds. ine the boat for structural damage. Tighten any
However, high speed impacts with rigid underwater loosened hardware. If the collision occurred in the
objects like pilings or boulders can be beyond the water, proceed slowly to harbor. Before boating
capability of the absorption system. Such impacts again, have your Dealer thoroughly inspect all com-
can result in serious damage to your engine and in- ponents.
jury to boat occupants from the engine or its parts
entering the boat. Occupants can also be ejected or
injured by falling against portions of the boat as a WARNING
result of rapid deceleration following impacts. When
boating in unfamiliar, shallow, or debris-laden wa-
ters, seek information on safe boating areas and Failure to inspect for damage could result in
navigation hazards from a reliable local source. Re- sudden, unexpected component failure,
duce your speed and keep a sharp lookout! loss of boat control, and personal injury.
Unrepaired damage could reduce your boat
and engine’s ability to resist future impacts.
STORING
Operation - 33
SPECIAL OPERATING CONDITIONS Shallow Water
IMPORTANT: Serious engine damage will occur if
Salt Water the gearcase is allowed to drag on the waterway
Flush the engine internally after use in salt, polluted bottom.
or brackish water to help prevent mineral deposits
from clogging cooling passages. Your outboard has Freezing Weather
a built-in flushing port to facilitate flushing. Refer to
Flushing. DURING operation in freezing weather, keep the
gearcase submerged at all times.
During use in salt or brackish water, additional an-
odic protection for the boat and outboard may be re- Upon removing your motor from the water, leave it
quired. in a vertical position until its cooling system is
drained.
During long periods of mooring, tilt the gearcase out
of the water — except in freezing temperatures. IMPORTANT: Water that has leaked into the gear-
Upon removal from salt water, leave it in a vertical case, or remained in the cooling system or other
position until its cooling system has drained. components can freeze, causing serious engine
damage.
Weedy Water IMPORTANT: If your outboard’s gearcase is
Weeds block water intakes and cause your out- equipped with an integral speedometer pickup, all
board to overheat. Weeds on the propeller create water must be cleared from the hose to prevent
vibration and reduce boat speed. gearcase damage. Refer to Off-Season Storage.
Run at slow speeds and in REVERSE frequently to
clear weeds from the propeller and water intakes. Submerged Engine
Check the water pump indicator often. If your engine has been under water, have it ser-
If REVERSE operation does not clear away weeds, viced immediately upon recovery. If immediate
SHUT OFF the engine. Remove weeds from pro- service is unavailable, resubmerge it in fresh water
peller area and water intakes before operating at to avoid prolonged exposure to the atmosphere.
higher speed. After submersion, all boat and engine electrical, fu-
el, and oiling systems must be inspected for signs
Boat Bottom and Engine External Finish of water intrusion. Your Dealer should perform this
service.
The condition of your boat’s bottom affects perfor-
mance. A covering of marine growth reduces
speed. For maximum performance, keep the boat’s Dual Engine Operation
running surface clean by wiping it dry after each use When you are maneuvering at slow speed, be sure
and washing it occasionally. both engines are running, even if one or both are in
After operating your outboard, rinse it with fresh wa- NEUTRAL.
ter and wipe it dry. Apply Evinrude/Johnson anti- If it is necessary to return to harbor with one engine
corrosion spray to any surface subject to corrosion, not running, you should not attempt to operate the
but avoid the anticorrosion anode(s). boat above planing speed. Tilt the inoperative en-
Periodically, wash the entire boat and outboard with gine high enough to keep its propeller out of the wa-
soapy water and apply a coat of automotive wax. ter.
Leave the engine cover in place when washing the
outboard.
Under Tow
High Altitude Should you require a tow from another boat:
• Shift your engine to NEUTRAL;
IMPORTANT: Your engine’s EMM will automatical- • Tilt its gearcase out of the water; and
ly compensate for changes in altitude. However, if • Off-load all persons into another boat.
you consistently boat above 3000 ft. (900 m), you
may experience a slight loss of power due to re- Keep towing speed slower than planing speed.
duced air density.
If your engine drops below the recommended RPM
operating range at full throttle, have your Dealer se-
lect a lower pitch propeller.
If you return to sea level, have your Dealer install
the original propeller and verify correct RPM oper-
ating range.
34 - Operation
MAINTENANCE
Maintenance, replacement, or repair of the EPA Emission Regulations
emission control devices and systems may be
performed by any marine SI (spark ignition) en- All new 2002 and more recent Johnson outboards
gine repair establishments or individual. manufactured by BMCA are certified to the EPA as
conforming to the requirements of the regulations
for the control of air pollution from new watercraft
ENGINE EMISSIONS INFORMATION marine spark ignition engines. This certification is
contingent on certain adjustments being set to fac-
tory standards. For this reason, the factory proce-
Manufacturer’s Responsibility dure for servicing the product must be strictly
followed and, whenever practicable, returned to the
Beginning with 1999 model year engines, manufac- original intent of the design. The responsibilities list-
turers of marine engines must determine the ex- ed above are general and in no way a complete list-
haust emission levels for each engine horsepower ing of the rules and regulations pertaining to the
family and certify these engines with the United EPA requirements on exhaust emissions for marine
States of America Environmental Protection Agen- products. For more detailed information on this sub-
cy (EPA). An emissions control information label, ject, you may contact the following locations:
showing emission levels and engine specifications,
must be placed on each engine at the time of man-
ufacture. VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Dealer’s Responsibility Engine Programs and Compliance Division
When performing service on all Johnson outboards Engine Compliance Programs
that carry an emissions control information label, Group (6403J)
adjustments must be kept within published factory 401 M St. NW
specifications.
Washington, DC 20460
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed cer- VIA EXPRESS or COURIER MAIL:
tification standards. Office of Mobile Sources
Dealers are not to modify the engine in any manner Engine Programs and Compliance Division
that would alter the horsepower or allow emission Engine Compliance Programs
levels to exceed their predetermined factory speci-
fications. Group (6403J)
501 3rd. St. NW
Exceptions include manufacturer’s prescribed
changes, such as altitude adjustments, for exam- Washington, DC 20001
ple.
EPA INTERNET WEB SITE:
Owner Responsibility www.epa.gov
The owner/operator is required to have engine
maintenance performed to maintain emission levels
within prescribed certification standards. WARNING
The owner/operator is not to, and should not allow
anyone to, modify the engine in any manner that Only perform service procedures which are
would alter the horsepower or allow emissions lev- detailed in this Operator’s Guide. Attempt-
ing to perform maintenance or repair on
els to exceed their predetermined factory specifica-
tions. your outboard if you are not familiar with
the correct service and safety procedures
Tampering with the carburetor to change horse- could cause injury or death.
power or modify emission levels beyond factory
settings or specifications will void the product war-
ranty.
Maintenance - 35
10-HOUR INSPECTION IMPORTANT: Provide a water supply to the engine
and start it. Run the engine at idle only.
After 10 hours of operation, your new engine will be To run the engine on a flusher, refer to Flushing.
broken in and its mechanical parts will have seated. To avoid difficulty when restarting, never run the
At that time, all systems should be checked and any engine with the fuel hose disconnected or run the
adjustments needed should be made. engine out of fuel.
Your Dealer will perform this 10-Hour Inspection at
your request and expense (based on local rates), Oil and Filter — Start the engine and run it at
according to what your engine needs — refer to En- least five minutes to warm the crankcase oil.
gine Maintenance and Inspection Schedule, 10- Stop the engine and drain the crankcase while the
Hour Inspection for a partial list. engine is warm. Refill it with Evinrude/Johnson Ul-
Follow consistent preventive maintenance by hav- tra 4-Stroke synthetic blend oil. Replace the oil fil-
ing your Dealer check and service your engine ter. Refer to Crankcase Oil and Filter. Restart the
once a year or after each 100 hours of operation, engine and run it for a few minutes to circulate the
whichever comes first. fresh oil.
IMPORTANT: It is very important that the bearing
surfaces be coated with clean oil before entering a
OFF-SEASON STORAGE period of storage, so be sure you run the engine af-
ter changing the oil.
You must protect against natural environmental Stop the engine.
conditions that can be damaging to an outboard
motor. Temperature and humidity changes while Spark Plugs — Remove and examine them.
your outboard motor is not in use can cause corro- Clean or discard them, if necessary. Refer to Spark
sion of internal engine parts when they are not pro- Plugs.
tected. Fuel remaining in your fuel tank and in the
engine will oxidize and weather which can result in Spray Evinrude/Johnson Storage Fogging Oil into
the spark plug holes.
loss of octane and can cause gum deposits in the
fuel system. Your warranty does not cover engine Slowly rotate the flywheel by hand to distribute the
failure caused by these conditions. We strongly rec- fogging oil and to drain the water from the water
ommend that you have your Dealer prepare your pump.
outboard for the off-season. Install spark plugs; tighten to specifications in
To do the off-season storage preparations yourself, Spark Plugs.
gather the supplies and perform the following steps:
Fuel filter(s) — Clean or change.
2+4 fuel conditioner
Triple-Guard grease Ignition, oil and fuel systems — Check for mis-
placed leads and damaged or deteriorated parts.
Ultra-HPF gearcase lubricant Be sure starter solenoid terminal boot and all con-
Storage Fogging Oil spray can nectors are in place.
Evinrude/Johnson Ultra 4-Stroke synthetic
blend oil
Stabilize the engine’s fuel supply with 2+4 fuel con-
ditioner during the last hours of operation to ensure
proper stabilization, following instructions on the
container for mixture. Be sure to run the engine
long enough for the treated fuel to reach the en-
gine.
WARNING
Prevent injury from moving engine compo-
nents. Before starting the engine:
Shift it to NEUTRAL.
Keep hands, clothes, and hair clear of pow-
erhead.
Remove the propeller if you use a flushing
device.
36 - Maintenance
Screws, bolts, nuts — Tighten any that are Lubrication — Refer to Lubrication to drain and
loose. refill the gearcase and for lubricating points on the
engine.
Propeller — Remove and examine. If damaged,
see your Dealer. Clean the propeller shaft and lubri- Touch up painted surfaces and wax the engine’s
cate it. Refer to Propeller. exterior. Store the engine on the boat (or an engine
stand) in a vertical, self-draining position.
Gearcase speedometer pickup, if equipped — If you cannot store the engine in the recommended
Disconnect the speedometer hose at the upper vertical position, be sure the cooling system is
connection. With air pressure no more than 25 psi drained completely.
(167 kPa), blow all water from the gearcase speed-
ometer pickup system. Reconnect speedometer IMPORTANT: Never place the gearcase higher
pickup after all the water has been removed. than the powerhead. Any water remaining in the ex-
haust passages can run into the cylinders and
cause serious damage.
If you remove an "installed" engine, examine all
hardware you loosened or removed from the en-
gine and its steering, throttle, and shift systems.
Replace damaged or missing parts with Evinrude/
Johnson Genuine Parts, or equivalent.
Battery — Remove it, clean it, check its condition
and water level, then charge it. Store it in a place
that’s cool and dry, out of direct sunlight. Check the
water level and charge it periodically during the
storage period.
Portable fuel tank — Disconnect the hose from
the tank. Remove the hose from the engine if the fit-
ting is a quick-disconnect. If not, and the hose is se-
cured to the engine, leave it connected. Secure the
hose to protect it.
WARNING
Store fuel tanks in a well-ventilated area,
away from heat and open flame. Prevent
escape of liquid or vapors which could acci-
dentally ignite. Close the filler cap vent
screw, if equipped. Be sure the discon-
nected fuel hose does not drip.
Maintenance - 37
PRE-SEASON SERVICE
WARNING
Remove your outboard from storage and prepare it
for a season of reliable service by performing a gen- Do not use a booster battery and jumper
eral check and a few preventive maintenance pro- cables to start the engine. Fumes vented
cedures. can cause explosion and fire, resulting in
Examine all loosened or removed hardware and property damage, serious injury, or death.
any steering, throttle, and shift systems. Replace
damaged or missing parts with Evinrude/Johnson
Genuine Parts or equivalent. Refer to Engine Monitoring and review your en-
gine’s warning system self-test routine. During your
preseason start-up, make sure the warning system
WARNING self-tests properly. If it does not, see your Dealer.
Follow Engine Starting and start the engine. Let it
Failure to carefully reattach the outboard idle while you:
and its control systems with factory-speci-
fied hardware can result in sudden, unex- Observe running quality – if poor, refer to Trouble
pected loss of boat control. Check Chart or see your Dealer.
Observe water pump operation. Water must flow
from the water pump indicator in a steady stream. If
Engine Oil — Check the engine oil level. Refer to it does not, shut OFF the engine and investigate.
Crankcase Oil and Filter. Refer to Engine Overheating.
With the propeller removed, check the gearcase for Stop the engine and check the fuel system for
leakage. If leakage is evident, the gearcase seals leaks.
should be replaced. See your Dealer.
Anticorrosion anodes — Check condition. Refer WARNING
to Anticorrosion Anodes.
Install the propeller unless you will run the engine Failure to check for fuel leakage could allow
on a flusher for your pre-season servicing. If so, in- a leak to go undetected, resulting in fire or
stall the propeller after you shut OFF the engine explosion.
and disconnect the flusher. Refer to Flushing.
Refer to Propeller to install the propeller.
WARNING
Prevent accidental contact with a rotating
propeller; always remove it when using a
flusher to run the engine.
38 - Maintenance
BATTERY
Maintenance - 39
CRANKCASE OIL AND FILTER Changing the Filter
See your Dealer.
Initial Fill
Changing the Oil
IMPORTANT: 4-Stroke outboards are shipped
without oil in the crankcase. You must add oil to Refer to Engine Maintenance and Inspection
the crankcase before starting the engine for the Schedule for frequency.
first time. It is recommended you add Evinrude/ After the first 10 hours of operation, replace the
Johnson 4-Stroke outboard oil. Refer to Changing break-in lubricant with Evinrude/Johnson Ultra 4-
the Oil for acceptable substitute lubricants. Stroke synthetic blend oil. Refer to 10-Hour In-
BEFORE filling the crankcase for the first time, be spection.
sure it is empty by checking the dipstick. Refer to If Evinrude/Johnson Ultra 4-Stroke synthetic blend
Checking. oil is temporarily unavailable, you may use
After the first 10 hours of operation, replace the Evinrude/Johnson 4-Stroke outboard oil or an
break-in lubricant with Evinrude/Johnson Ultra 4- equivalent FC-W-approved 10W-40 or 10W-50 oil.
Stroke synthetic blend oil. Refer to 10-Hour In- Drain (or siphon) the old oil after running the engine
spection. to warm it. Warm oil flows more quickly and com-
pletely, containing more suspended sludge than
cold oil. If you change the oil only once a season,
Checking time the work so the engine contains clean oil dur-
Check the oil level when the engine is cold to en- ing storage.
sure an accurate reading.
1) Place the engine in a vertical position and re-
move the upper engine cover. CAUTION
2) Remove the dipstick, wipe it clean, and install
it. Used motor oil may be harmful. Avoid pro-
3) Move the dipstick again and locate the line of longed and repeated skin contact. Wash
oil. If the line of oil is not between the ADD affected skin with soap and water.
and the FULL marks, you must add or re-
move oil as indicated. If the line of oil level is
near the lower limit, add enough oil to raise 1) Place the engine in a vertical position and re-
the level to the upper limit. move the upper engine cover.
2) Unscrew and remove the oil fill cap.
2
1 1
1. Add
2. Full 1. Oil fill cap
4) Securely install the dipstick and wipe up any
spilled oil.
IMPORTANT: Operating the engine with too much
or too little oil in the crankcase will damage it.
40 - Maintenance
3) Hold a suitable container under the oil drain ADJUSTMENTS
screw. Remove the screw and drain the re-
servior. Before you reinstall the screw, re-
place the gasket with a new one (several Trim Tab
were included in your tool kit). Reinstall the
screw and tighten it securely.
WARNING
Improper trim tab adjustment can cause dif-
ficult steering.
The trim tab is also an anti-corrosion anode.
Disintegration of the anode can effect boat
2 handling and performance. Make sure the
trim tab is in good condition and adjust
properly.
1
A propeller will generate steering torque when the
propeller shaft is not running parallel to the water’s
surface. The trim tab is adjustable to compensate
for this steering torque.
1. Oil drain screw
2. Gasket IMPORTANT: A single trim tab adjustment will re-
lieve steering effort under only one set of speed,
4) Pour the recommended oil into the oil fill until motor angle and load conditions. No single adjust-
it reaches the upper mark on the dipstick. Re- ment can relieve steering effort under all speed,
fer to Engine Specifications for crankcase motor angle and load conditions. If the boat pulls to
capacity. the left or right when its load is evenly distributed,
5) Replace the oil fill cap and clean any spilled adjust the trim tab as follows:
oil off the engine and your skin. With the motor shut OFF, loosen the trim tab
6) Reinstall the upper cover. screw. If the boat pulled to the right, move the rear
7) Supply water to the cooling system and run of the trim tab slightly to the right. If the boat pulled
the engine at idle to check for leaks, especial- to the left, move the rear of the trim tab slightly to
ly around drain screw and oil fill cap. Correct the left.
any problems.
8) Stop the engine and recheck crankcase oil
level using the dipstick. Add oil as indicated.
2
1
Maintenance - 41
High motor installations — The trim tab might LUBRICATION
be above the water when the motor is trimmed out.
Steering effort might increase. Steering effort will
be reduced if you trim the motor in and submerge Gearcase
the trim tab.
Replace gearcase lubricant after first 10 hours of
Dual standard rotation motors — Move both of operation. Check level and condition of lubricant af-
the trim tabs equally and in the same direction. ter next 50 hours of operation. Add lubricant if nec-
essary.
Dual motors (one counter and one standard ro- Thereafter, check level and condition of lubricant
tation) — Set both trim tabs to the center position. every 50 hours. Replace lubricant every 100 hours
of operation or once each season, whichever oc-
Throttle Friction curs first. Refill with Ultra-HPF gearcase lubricant.
If not available, Hi-Vis™ or other marine gearcase
Adjust throttle friction on your remote control to lube can be used, however, long term durability
maintain its position and prevent unwanted throttle may be affected with continued use. See your Deal-
“creep” under normal operating conditions. er.
To adjust, start engine and move control handle
into FORWARD throttle range. While underway, IMPORTANT: The recommended gear lubricants
turn adjustment knob clockwise to increase friction. include special additives for marine applications.
The friction adjustment is effective only in the Do not use automotive gear lubricants, 2-stroke or
FORWARD throttle range. 4-stroke engine oil, or any other oil or grease for
gearcase applications.
With motor in normal operating position:
1) Remove drain/fill plug and lubricant level plug
from side of gearcase and completely drain
gearcase of old lubricant.
2) Examine drained lubricant for metal filings,
milky appearance, or black color with burnt
odor. If old lubricant has any of those charac-
teristics, see your Dealer. If drained lubricant
is in good condition, continue.
3) Place tube of lubricant in drain/fill hole and fill
1 slowly until lubricant appears at lubricant lev-
el hole. See Engine Specifications for gear-
case capacity.
42 - Maintenance
4) Install lubricant level plug before removing Power Trim and Tilt Fluid Reservoir
tube from drain/fill hole. Drain/fill plug can
then be installed without loss of lubricant. Tilt the motor up and engage the tilt support. De-
pending on your model, refer to Power Trim and
5) Securely tighten both plugs. Tilt. Remove filler cap and check fluid level. If nec-
essary, add enough Evinrude/Johnson Power Trim/
Tilt and Power Steering Fluid to bring the fluid level
2 even with the bottom of the fill cap hole when the
unit is at full tilt.
1
1
1. Drain/fill plug 2
2. Lubricant level plug
WARNING
Failure to regrease as recommended could
result in steering system corrosion. Corro-
sion can affect steering effort, making oper-
ator control difficult.
Maintenance - 43
FUSES
WATER PRESSURE
1
An optional water pressure gauge is recommended 1. Fuse
to monitor cooling system pressures. Noticing 2. Spare fuse holder
changes in water pressure can help prevent engine
overheating. The water pressure gauge must be
connected at the correct point to ensure the most Fuse Failure
accurate pressure readings. Follow the installation A minor electrical problem can blow a fuse. Re-
instructions included with the water pressure place it with a fuse of the same rating.
gauge.
Repeated failures of fuses in the same position in-
dicate a serious problem. Do not replace it with
FUEL LINE FILTER higher rated fuses; see your Dealer for service.
1. Filter
44 - Maintenance
SPARK PLUGS PROPELLER
WARNING WARNING
The ignition system presents a serious When servicing the propeller, always shift
shock hazard. The primary circuit operates the outboard to NEUTRAL position, turn the
in excess of 250 volts; the secondary circuit key switch OFF and disconnect battery pos-
operates in excess of 25,000 volts. Use cau- itive (+) cable so the engine cannot be
tion to avoid injury from shock or injury started accidentally.
resulting from your reaction to shock. Do
not handle primary or secondary ignition
components while the engine is cranking or IMPORTANT: Apply Triple-Guard grease to the en-
running. tire propeller shaft before installing the propeller. At
least annually, remove the propeller and check for
debris. Clean the shaft and regrease it before rein-
Inspect spark plugs periodically. Replace if elec- stalling a propeller.
trodes are badly worn, insulators are cracked, or if
they are badly fouled.
Installation
To remove spark plugs, twist and remove all spark
plug leads. Unscrew spark plug from cylinder head. Slide thrust washer onto shaft with shoulder facing
aft.
To install spark plugs, wipe spark plug seats clean
with a clean rag. Install spark plugs finger tight, then Slide propeller onto shaft, engaging the splines and
tighten to specified torque. Refer to Engine Speci- seating it on the thrust washer.
fications. Slide spacer onto the shaft and engage the propel-
ler shaft splines.
IMPORTANT: Avoid engine damage by installing
spark plugs into COOL cylinder head and not over- Slide washer onto propeller shaft.
tightening. Wedge a block of wood between the propeller
Before installing the spark plug lead, apply a light blade and the anti-ventilation plate.
coat of Triple-Guard grease to the ribbed portion of
the spark plug. This will help prevent corrosion be-
tween the spring terminal and the spark plug.
Maintenance - 45
Continue to tighten propeller nut until nut slots and ANTICORROSION ANODES
cotter pin hole are aligned. Install new cotter pin
and bend ends to secure.
Your motor is equipped with one or more anodes
that protect it from galvanic corrosion. Refer to Fea-
tures for anode location. Disintegration of the an-
ode is normal and indicates it is working. Check
each anode periodically. Replace anodes smaller
than 2/3 their original size. See your Dealer for re-
placements.
2
3
4
1
1 5
1. Thrust bushing
2. Spacer
3. Washer 1
4. Cotter pin
5. Propeller nut
Repair
If your propeller hits a solid object, the impact is par- 1
tially absorbed by the rubber bushing in the hub to
help prevent damage to the engine. A strong impact
can damage the hub and propeller blades. Damage
to blades can cause unusual and excessive vibra-
tion. Damage to the hub can cause excessive en-
gine RPM with little forward movement.
IMPORTANT: Avoid or limit operation using a dam-
aged propeller. Carry a spare propeller.
Keep your propeller in good condition. Use a file to
smooth slight damage to blade edges. See your
Dealer for repair of serious damage. 1. Anode
Galvanic corrosion destroys underwater metal
parts and can occur in fresh or salt water; however,
salt, brackish and polluted waters will accelerate
corrosion.
Metal-based antifouling paint on the boat or motor
and the use of improperly installed shore power in
the area of your moored boat will also accelerate
corrosion.
IMPORTANT: NEVER paint the anode, its fasten-
ers, or its mounting surface. Painting will reduce its
corrosion protection.
46 - Maintenance
BONDING WIRES Drain the gasoline from the vapor separator as fol-
lows:
Bonding wires are used to electrically connect the 1) Remove the motor cover and rubber seal.
engine components so they exist in a common 2) Remove the seven bolts on the starboard cov-
ground circuit. This allows them to be protected er, then remove cover.
against electrolysis by the anodes. These wires and 3) Pull the drain hose end out.
their terminals should be checked periodically to be 4) Loosen the vapor separator drain screw and
sure they have not been damaged. drain the gasoline into a suitable container.
1
1. Drain hose
2. Drain screw
WARNING
Use a proper, safe container to store any
gasoline drained from the outboard motor.
Motor Transporting
Vertical transport
Attach the clamp bracket to a stand by securing
transom bolts.
Maintenance - 47
TROUBLE CHECK CHART
IMPORTANT: If you are unable to identify or solve the problem, contact your Dealer.
48 - Maintenance
NOTES
Maintenance - 49
ENGINE MAINTENANCE AND INSPECTION SCHEDULE
Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the
product’s life span. The following maintenance chart provides guidelines for engine maintenance and in-
spection scheduled to be performed by you and/or by an authorized Dealer. The schedule should be ad-
justed according to operating conditions and use.
The recommended lubricants have been formulated to protect bearings, gears and engine components.
They must be used to avoid damage caused by improper lubrication.
IMPORTANT: Schedules for rental operations, commercial applications or high hour use will require
greater frequency of inspection and maintenance.
or Biannually
or 6 months
or Annually
Inspection
Each Use
10-Hour
Engine Care
Description Product
Mechanical steering, lubricate (1) 7 Every 60 days / Every 30 in Saltwater
Tilt tube, inspect and lubricate (1) 7 Every 60 days / Every 30 in Saltwater
Swivel bracket / tilt support bracket, inspect and 7 Every 60 days / Every 30 in Saltwater
lubricate (1)
Throttle and shift linkage, inspect and lubricate (1) 7 Every 60 days / Every 30 in Saltwater
Remote control cables, lubricate (1) 7 Every 60 days / Every 30 in Saltwater
Lubrication and corrosion protection for metallic 4 Every 60 days / Every 30 in Saltwater
components
Battery connections and condition, verify 7 O D
SystemCheck self-test and warning horn, verify O D
operation
Anticorrosion anodes, verify operation O D
Water intake screens, verify condition O D
Overboard water pump indicator, verify operation O D
Steering system check, verify function O D
Throttle and shift operation, verify function O D
Emergency stop circuit and lanyard, verify function O D
Crankcase oil level, check O D
Flush cooling system O
Operator’s Guide, onboard O
Engine upper and lower motor covers, clean and wax O
Operator’s Guide, review O
Fuel and oil system components, inspect and repair D D
leaks (2)
Fastener inspection, tighten loosened components D D
Gearcase lubricant, replace 5 D D
Thermostat, inspect and verify operation (2) D D
Power tilt/trim fluid, inspect fluid level 6 D D
Engine to transom mounting hardware, re-torque D D
Electrical and ignition wires and connections, inspect D D
50 - Maintenance
Engine Maintenance and Inspection Schedule
Frequency
or Biannually
or 6 months
or Annually
Inspection
Each Use
10-Hour
Engine Care
Description Product
Powerhead synchronization and linkage, inspect (2) 7 D D
Access EMM information, resolve service codes D D
Breather line, inspect D D
Crankcase oil, replace (3) 11 D D
Valve tappet clearance, inspect (2) D D
Crankcase oil filter, replace D D
Bonding wires, inspect D
Gearcase lubricant, inspect fill level and condition of 5 D
lube
Starter pinion shaft, inspect and lubricate (4) 9 D
Propeller shaft splines, inspect and lubricate 7 D
Spark plugs, replace (2) D
Decarbonize 10 D
Timing belt, inspect D
Driveshaft splines, inspect and lubricate 8 D
Water pump, inspect and replace D
Ignition timing, check D
Fuel mixture, check D
Low pressure fuel filter, replace D Every 400 hours or biannually
Timing belt, replace D Every 800 hours or four years
High pressure fuel filter, replace D Every 1000 hours
Maintenance - 51
Bombardier Recreational Products
52 - Maintenance
CHANGE OF ADDRESS / CHANGE OF OWNERSHIP
If your address has changed or if there has been a change of ownership, be sure to fill out and mail the
card provided on this page.
Such notification is likewise necessary for your own safety even after expiration of the original warranty,
since BMCA will be in a position to contact you if correction to your outboard becomes necessary.
Outside the U.S. and Canada, this card should be sent to the Bombardier Recreational Products division
where the outboard was registered. Please contact your Dealer or distributor.
Serial Number
Address
City State
Phone number
Signature Date
Address
City State
Phone number
Signature Date
000063
Maintenance - 53
Bombardier Motor Corporation of America
54 - Maintenance
Bombardier Recreational Products
Maintenance - 55
Operator’s Guide
Confirmation of Receipt
Your Dealer
Name:
Address:
Upon delivery of your new Evinrude/Johnson Outboard, complete and sign the form hereunder. Your
Dealer will take receipt of the form for their records.
Receipt
Name:
Address:
Signature:
Date:
56 - Maintenance
Readiness Test and a Final Word to the Owner/Operator
The Operator’s Readiness Test....
1. Did you read this Guide from front cover to rear cover?
2. Are you ready to take responsibility for the safe operation of your boat and motor?
3. Do you understand all the safety precautions and instructions contained in this Guide?
4. Do you understand that this Guide contains essential information to help prevent personal injury and
damage to equipment?
5. Are you ready to follow the recommendations in this Guide and take a boating safety course before
you operate your boat and motor?
6. Do you know who to ask if you have any questions about your boat and motor?
7. Do you know your local marine traffic laws?
8. Do you understand that human error can be caused by carelessness, fatigue, overload, preoccupa-
tion, unfamiliarity of operator with the product, drugs and alcohol, just to name a few?
WARNING
It is impossible for this Guide to cover every hazardous situation you may encounter; how-
ever, your understanding of and adherence to essential information contained in this Guide
will build good judgment when boating. Always be alert and careful: a good foundation for
safety.
2005
4 Stroke
4/5/6 HORSEPOWER
R4, RL4
*5035765* ! WARNING