000000*
2004
Operator's Guide
*0000000*
25/30 HORSEPOWER
R, RL, TE, TEL
Our First Words to the Owner/Operator
This Operator’s Guide is an essential part of your Johnson outboard. It contains pertinent information
which, if followed, will provide you with a thorough understanding needed for proper operation, maintenance, care and above all safety!
The safety section of this Guide comes first because it is our first priority and it should be yours too. It is
strongly recommended that you read this Guide from front cover to rear cover. Following this recommendation will assure the completeness of the information that is essential to your safety, the safety of any
passengers and other boaters. An Operator’s Readiness Test has been prepared on the last page of this
Guide.
Be safe! All passengers should be familiar with the proper operation of your boat and Johnson outboard.
Be certain they fully understand and respect the controls and operation. Each operator is responsible for
the safety of all passengers and other boaters. Please make safety your first priority and complete a boating safety course through your local Coast Guard, Power Squadron, Red Cross or State Boating Law
Agency.
The pleasures of owning and operating a Johnson outboard can be significant. We strongly believe the
rewards for following our recommendations will be worthwhile. Remember that YOU are the key to safety.
Good safety practices not only protect you but also protect the people around you.
Having fun is what it’s all about and, with your cooperation, the pertinent information in this Guide can ensure a safe and enjoyable experience.
Enjoy the great outdoors on the water...
WARNING
Be careful! Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, 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:
2+4® fuel conditioner
Renegade® bass
CarbX™
S.L.O.W.™
Evinrude®
SST®
Evinrude®/Johnson® anti-corrosion spray
System Check®
Evinrude®/Johnson® Genuine Parts
Touch-Trim™
Evinrude®/Johnson® XD25™ formula
Triple-Guard® grease
Hi-Vis® gearcase lubricant
Twist-Grip™
Johnson®
Ultra-HPF™ gearcase lubricant
QuikStart™
Viper™
0-
Contents
GENERAL INFORMATION ................................................................................................... 2
SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2
PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4
BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD
ENGINES SOLD IN THE UNITED STATES AND CANADA .............................................................................. 5
BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD
ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA .................................................................. 8
FEATURES ............................................................................................................................................................... 10
ENGINE SPECIFICATIONS ...................................................................................................................................... 12
EMERGENCY STOP SWITCH .................................................................................................................................. 13
FUEL AND OIL ................................................................................................................... 14
FUEL .........................................................................................................................................................................
OIL .............................................................................................................................................................................
ADDITIVES ................................................................................................................................................................
FUEL/OIL RATIO ......................................................................................................................................................
MIXING FUEL AND OIL ............................................................................................................................................
FUEL SYSTEMS .......................................................................................................................................................
BREAK-IN (10 HOURS) ............................................................................................................................................
14
14
15
15
15
16
16
ENGINE STARTING ........................................................................................................... 17
BEFORE START-UP .................................................................................................................................................
ENGINE STOPPING .................................................................................................................................................
SHIFTING AND SPEED CONTROL .........................................................................................................................
EMERGENCY STARTING ........................................................................................................................................
FUEL ECONOMY ......................................................................................................................................................
17
20
21
21
23
OPERATION ....................................................................................................................... 24
MOTOR ANGLE ADJUSTMENT ..............................................................................................................................
TRAILERING .............................................................................................................................................................
TILTING AND TILT SUPPORT .................................................................................................................................
SHALLOW-WATER DRIVE ......................................................................................................................................
PROPELLER SELECTION .......................................................................................................................................
MOORING .................................................................................................................................................................
FLUSHING ................................................................................................................................................................
ENGINE OVERHEATING ..........................................................................................................................................
IMPACT DAMAGE ....................................................................................................................................................
STORING ..................................................................................................................................................................
SPECIAL OPERATING CONDITIONS .....................................................................................................................
24
24
24
25
27
27
27
28
29
29
30
MAINTENANCE .................................................................................................................. 31
10-HOUR INSPECTION ............................................................................................................................................
OFF-SEASON STORAGE ........................................................................................................................................
PRE-SEASON SERVICE ..........................................................................................................................................
BATTERY ..................................................................................................................................................................
ADJUSTMENTS ........................................................................................................................................................
LUBRICATION ..........................................................................................................................................................
FUEL PUMP FILTER ................................................................................................................................................
SPARK PLUGS .........................................................................................................................................................
PROPELLER .............................................................................................................................................................
ANTICORROSION ANODES ....................................................................................................................................
AC LIGHTING ...........................................................................................................................................................
TROUBLE CHECK CHART ......................................................................................................................................
ENGINE MAINTENANCE AND INSPECTION SCHEDULE .....................................................................................
INSTALLATION ........................................................................................................................................................
31
31
32
33
34
35
37
37
38
39
40
41
42
46
© 2003 Bombardier Motor Corporation of America. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Motor Corporation of America or its affiliates.
1
GENERAL INFORMATION
SAFETY — THE RIGHT PLACE TO GET
STARTED
This Operator’s Guide contains essential information to help prevent personal injury and damage to
equipment. It will acquaint the operator and passengers with the Evinrude/Johnson outboard and
its controls, operation, maintenance and boating
safety measures. Make sure all operators read, understand and follow the contents. This Guide
should be kept in a waterproof bag with the product
at all times during operation. If the product ownership is transferred, this Guide should be forwarded
to the subsequent owners.
This Operator’s Guide uses the following signal
words identifying important safety messages.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
DANGER
Indicates an imminently hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
A responsible, educated boater will fully appreciate
the pleasures of boating and will be a safe boater.
Boating Safety Classes are conducted by the U.S.
Coast Guard Auxiliary, the U.S. Power Squadron
and some Red Cross Chapters. For information
about classes, call toll free 1-800-336-BOAT. For
additional information about boating safety and regulations call: U.S. Coast Guard Boating Safety Hotline 1-800-368-5647. Outside North America
please contact your DEALER or distributor for details about boating safety.
SAFETY MEASURES — General
To fully appreciate the pleasures, enjoyment
and excitement of boating there are some basic rules that should be observed and followed
by any boater. Some rules may be new to you
and others may be common sense or obvious... irrespective, take them seriously! Failure to follow this safety information and safe
boating rules could result in injury to you, your
passengers or other water users.
Become completely familiar with the control
and operation of your boat and motor before
embarking on your first trip or taking on a passenger(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 applying the throttle above idle speed. As the operator, you are in control and responsible for
safe operation.
SAFETY MEASURES — Operation
Be sure at least one of your passengers
knows how to handle your boat in case of an
emergency.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or
moderate personal injury or property damage. It also may be used to alert against
unsafe practices.
IMPORTANT: Identifies information that will help
prevent damage to machinery and appears next to
information that controls correct assembly and operation of the product.
Although the mere reading of such information
does not eliminate the hazard, the understanding
and application of the information will promote the
correct use of your outboard engine.
2 - General Information
All passengers should know the location of
emergency equipment and how to use it.
All safety equipment and personal flotation
devices must be in good condition and suitable for your type of boat. Always comply with
the regulations that apply to your boat.
Contact with rotating propeller is likely to result
in serious injury or death. Do not allow anyone
near a propeller, even when the engine is off.
Propeller blades can be sharp and can continue to turn even after the engine is shut off. Always shut off the engine when boat is near
people in the water.
Whenever running the engine, assure there is
proper ventilation to avoid the accumulation of
carbon monoxide (CO), which is odorless, colorless, and tasteless, and can lead to unconsciousness, brain damage, or death if inhaled
in sufficient concentrations. CO accumulation
can occur while docked, anchored, or underway, and in many confined areas such as the
boat cabin, cockpit, swim platform, and heads.
It can be worsened or caused by weather,
mooring and operating conditions, and other
boats. Avoid exhaust fumes from your engine
or other boats, provide proper ventilation, shut
off your engine when not needed, and be
aware of the risk of backdrafting and conditions that create CO accumulation. In high
concentrations, CO can be fatal within minutes. Lower concentrations are just as lethal
over long periods of time.
Do not operate your boat if you are under the
influence of drugs or alcohol.
High performance boats have a high powerto-weight ratio. If you are not experienced in
the operation of a high performance boat, do
not attempt to operate one at, or near, its top
speed until you have gained that experience.
For more information, see your Evinrude/
Johnson DEALER for a copy of Introduction
to High Performance Boating, P/N 335763.
SAFETY MEASURES — Installation and
Maintenance
Outboard Installation
Proceed with caution and at very low speed in
shallow water. Grounding or abrupt stops may
result in personal injury or property damage.
Also be alert for debris and objects in the water.
The outboard must be correctly installed. Failure to correctly install the outboard could result in serious injury, death or property
damage. We strongly recommend that your
DEALER install your outboard to ensure proper installation.
Be familiar with the waters you are operating
in. The gearcase of this outboard extends below the water surface and could potentially
come in contact with underwater obstructions.
Contact with underwater obstructions may result in loss of control and personal injury.
Do not overpower your boat by using an engine that exceeds the horsepower indicated
on the boat’s capacity plate. Overpowering
could result in loss of control. If your boat has
no capacity plate, contact your DEALER or the
boat’s manufacturer.
Avoid standing up or shifting weight suddenly
in light weight boats.
Keep your passengers seated in seats. The
boat’s bow, gunwale, transom and seat backs
are not intended for use as seats.
Insist on the use of personal flotation devices,
approved by the U.S. Coast Guard, by all passengers when boating conditions are hazardous, and by children and nonswimmers at all
times.
Respect no wake zones, rights of other water
users and the environment. As the "skipper"
and owner of a boat you are responsible for
damage to other boats caused by the wake of
your boat. Allow no one to throw refuse overboard.
Know the marine traffic laws and obey them.
Remember, gasoline fumes are flammable
and explosive. Always adhere to the fueling
procedure contained in this Operator’s Guide
and those given to you by the fueling station.
Always verify fuel level before use and during
the ride. Apply the principle of 1/3 fuel to destination, 1/3 back and 1/3 reserve fuel supply.
Do not carry spare fuel or flammable liquids in
any storage or engine compartments.
Maintenance
When replacement parts are required, use
Evinrude®/Johnson® Genuine Parts or parts
with equivalent characteristics, including type,
strength and material. Using substandard
parts could result in injury or product malfunction.
Only perform service procedures which are
detailed in this Operator’s Guide. Attempting
to perform maintenance or repair on your outboard if you are not familiar with the correct
service and safety procedure could cause personal injury or death. Further information can
be obtained from your authorized Evinrude/
Johnson DEALER. In many instances proper
tools and training are required for certain service or repair procedures.
Maintain your boat and engine in top condition
at all times. Adhere to the Engine Maintenance and Inspection Schedule.
Operate your boat and outboard prudently
and have fun. Do not forget that all persons
must assist other boaters in case of emergency.
Prevent injury from contact with rotating propeller; remove propeller before flushing or before performing any maintenance.
General Information - 3
PRODUCT REFERENCES,
ILLUSTRATIONS AND
SPECIFICATIONS
WARNING
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts
with equivalent characteristics, including
type, strength and material. Using substandard parts could result in injury or product
malfunction.
Bombardier Motor Corporation of America reserves
the right to make changes at any time, without notice, to features, specifications and model availability. The right is also reserved to change any
specification or part at any time without incurring
any obligation to update older models. The information in the Guide is based on the latest specifications available at the time of publication.
Photographs and illustrations used in this Guide
might not depict actual models or equipment but
are intended as representative views for reference
only. The continuing accuracy of this Guide cannot
be guaranteed.
Certain features of systems discussed in this Guide
might not be found on all models in all marketing areas.
Owner’s Identification
North America — At the time of purchase, your
DEALER will complete your outboard registration
forms. Your portion provides proof of ownership
and date of purchase.
Outside North America — See your DEALER or
distributor for details.
Model and Serial Numbers
The model and serial numbers appear on a plate attached to the stern bracket or swivel bracket.
Record your outboard’s:
Model Number ___________________________
Serial Number ____________________________
Purchase Date ___________________________
Ignition Key Number _______________________
4 - General Information
Stolen Outboards
North America — Report your outboard as stolen
to Customer and Dealer Support Services, 250 Sea
Horse Drive, Waukegan, IL 60085 U.S.A. Give the
outboard’s model and serial numbers and enclose
a copy of the police report.
Outside North America — Report the theft to the
Bombardier distributor where the outboard was registered.
Technical Literature
Bombardier Motor Corporation of America offers
technical literature specifically for your outboard. A
service manual, a parts catalog, or an extra Operator’s Guide can be purchased from your selling
DEALER. For the name and location of the nearest
Evinrude/Johnson DEALER in the United States
and Canada log on to www.evinrude.com or
www.johnson.com.
Declaration of Conformity
Bombardier Motor Corporation of America declares
that the outboard to which this Operator’s Manual
applies conforms to the essential requirements outlined in CE Machinery Directive 98-37-EC, as
amended.
George Broughton
Director of Outboards
BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD
ENGINES SOLD IN THE UNITED STATES AND CANADA
1. SCOPE OF THE LIMITED WARRANTY
Bombardier Motor Corporation of America* ("Bombardier") warrants its Johnson® 2-stroke outboard engines sold by authorized Johnson dealers in the fifty United States and Canada ("Product") from defects
in material or workmanship for the period and under the conditions described below.
2. WARRANTY COVERAGE PERIOD
This limited warranty will be in effect 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:
TWENTY-FOUR (24) CONSECUTIVE MONTHS for private, recreational use; or
TWELVE (12) CONSECUTIVE MONTHS for commercial use. 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 propellers, bear the standard Bombardier parts and accessories one-year limited warranty.
3. CONDITIONS TO HAVE WARRANTY COVERAGE
This warranty coverage is available only on Johnson 2-stroke outboard engines purchased as new and
unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred
("Dealer"), and then only after the Bombardier specified pre-delivery inspection process has been completed and documented by the purchaser and Dealer. Warranty coverage only becomes available upon
proper registration of Product by Dealer or owner.
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 warranty coverage hereunder. Such limitations are necessary in order to allow Bombardier 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. Bombardier may require proof of proper maintenance prior to authorizing warranty
coverage.
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 opportunity to repair the defect. The expenses of transporting Product to and from Dealer for warranty service 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 purchase 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 Bombardier.
General Information - 5
5. WHAT BOMBARDIER WILL DO
Bombardier's obligations under this warranty are limited to, at its sole discretion, repairing or replacing
parts of Product found to be defective in material or workmanship, in the reasonable judgment of Bombardier. Such repair or replacement of parts will be done without charge for parts and labor, at any authorized
Dealer. Bombardier's responsibility is limited to making the required repairs or replacements of parts with
new or Bombardier-certified re-manufactured parts. No claim of breach of warranty shall be cause for cancellation or rescission of the sale of Product to owner.
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.
Bombardier reserves the right to improve, modify or change Products from time to time without assuming
any obligation to modify Products previously manufactured.
6. EXCLUSIONS – The following are not warranted under any circumstances:
• Replacement of parts due to normal wear and tear;
• Routine maintenance parts and services including but not limited to: maintenance requirements, engine
and lower unit oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zinc
anodes, thermostats, timing belts, starter motor bushings, trim motor brushes, filters, propellers, propeller bushings and spark plugs;
• Damage caused by improper or lack of installation, maintenance, winterization and/or storage, failure
to follow the procedures and recommendations in the Operator's Guide;
• Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or use
of parts or accessories not manufactured or approved by Bombardier, which in its reasonable judgment,
are either incompatible with Product or adversely affect its operation, performance, or durability, or resulting from repairs done by a person that is not an authorized Dealer;
• Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation of
the Product in a manner inconsistent with the recommended operation described in the Operator's
Guide;
• Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalism
or any act of God;
• Operation without proper fuel, oil or lubrication, or with fuels, oils or lubricants which are not suitable for
use with the Product (see the Operator's Guide);
• Damage resulting from rust or corrosion;
• Damage caused from cooling system blockage by foreign material;
• Damage resulting from sand or debris in the water pump;
• Cosmetic or paint changes due to exposure to the elements.
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 WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY.
ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND
ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO:
expense for gasoline, expense for transporting Product to and from Dealer, removal of Product from a
boat and reinstallation, mechanic's travel time, in-and-out of water charges, slip or dock fees, trailering or
towing, storage, telephone, cell phone, fax or telegram charges, rental of a like or replacement Product or
boat during warranty services or down time, taxi, travel, lodging, loss of or damage to personal property,
inconvenience, cost of insurance coverage, loan payments, loss of time, loss of income, revenue or profits, or loss of enjoyment or use of Product.
SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTIFIED 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 warranty regarding Product other than those contained in this limited warranty and, if made, shall not be enforceable against Bombardier. Bombardier 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 warranty 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 Bombardier 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 Bombardier limited warranty, Bombardier
recommends 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 Customer Support Services, 250 Sea
Horse Drive, Waukegan, IL 60085, 1-847-689-7090.
Revision April 2003
* Engines sold in Canada are distributed and serviced by Bombardier Inc.
General Information - 7
BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD
ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA
For a copy of the Limited Warranty, see your Bombardier distributor/dealer authorized to distribute
Johnson 2-stroke products in the country in which the sale occurs.
If further assistance is required, please contact Bombardier Customer Support Services, 250 Sea Horse
Drive, Waukegan, Illinois, 60085, or the affiliate of Bombardier where the Product was registered for warranty.
8 - General Information
NOTES
General Information - 9
FEATURES
Electric Start Models
17
16
15
1
14
2
12
3
13
4
9
11
5
10
8
7
25
000152
Item
18
6
Description
Item
Description
1
Fuel Pump Filter
10
Positive Terminal Boot (1)
2
Water Pump Indicator
11
Battery Cable (1)
Clip and Lanyard Assembly
3
Steering Friction Screw
12
4
Tilt/Run Lever
13
Stop Button/Emergency Stop Switch
5
Angle Adjusting Rod
14
Emergency Restart Clip Storage
6
Lubricant Drain/Fill Plug
15
Shift Lever
7
Lubricant Level Plug
16
Electric Start Button (1)
8
Shallow-Water Drive Bracket
17
Electric Starter (1)
9
Clamp Screws
18
Emergency Start Cord
(1) Electric Start Models
10 - General Information
Manual (Rope) Start Models
33
34
35
36
21
22
32
23
31
24
19
30
29
25
28
26
27
20
Item
000153
Description
Item
Description
19
Mounting Hardware
28
Trim Tab
20
Fuel Tank
29
Anti-ventilation plate
21
Idle Speed Adjusting Knob
30
Anticorrosion Anode
22
Steering Handle and Twist-GripTM Throttle
31
Engine Cover Latch
23
Fuel Connector
32
Spark Plugs
24
Model and Serial Number Plate
33
Starter Cable Locking Tabs
25
Water Intakes
34
Starter Handle
26
Fish Line Trap
35
Primer Knob
27
Propeller (1)
36
AC Lighting Inlet
(1) Not supplied in all marketing areas
General Information - 11
ENGINE SPECIFICATIONS
25, 30 Models
Displacement
31.8 cu. in. (521 cc)
Engine Type
Two-Cycle, In-line, 2 Cylinder
Full Throttle Operating Range
25 – 4500 to 5500 RPM
30 – 5200 to 5800 RPM
Power (1)
25 – 25 HP (18.7 kw) @ 5000 RPM
30 – 30 HP (22.4 kw) @ 5500 RPM
Idle RPM in Gear (2)
800 ± 100
Ignition Timing – Idle (2)
W.O.T.
Not Adjustable
30° ± 1°
Exhaust Emission Control (2)
System per SAE J1930
EM (Engine Modification)
Fuel Requirements (2)
87 Pump Posted AKI (89 RON) – Refer to Fuel and Oil
Fuel/Oil Ratio
50:1
Ignition Features
S.L.O.W.™ (Speed Limiting Overheat Warning)
Starting
R, RL – Rope
TE, TEL – Electric start at engine
Battery, Minimum
360 CCA (465 MCA) with 90 minutes reserve capacity
OR 50 ampere-hour, 12 volt
Spark Plug (2)
Torque
Refer to ECI Label
18 to 21 ft. lbs. (24 to 28 N·m)
Alternator
TE, TEL – 4 Amps, Nonregulated
AC Lighting
(3)
Gearcase –Lubricant
Capacity
60 watts AC @ 12 volts
Evinrude/Johnson Ultra-HPF™ gearcase lubricant
12.2 fl. oz. (361 ml)
Propeller (4)
10 x 13 in. (25 x 33 cm)
Fuel Tank
Capacity – 6 U.S. gallons (22.7 liters)
Weight (5)
R – 117 lbs. (53 kg)
RL – 121 lbs. (55 kg)
TE – 123 lbs. (56 kg)
TEL – 126 lbs. (57 kg)
Transom Height
R, TE – 14 1/2 to 15 in. (36.8 to 38.1 cm)
RL, TEL – 19 1/2 to 20 in. (49.5 to 50.8 cm)
Sound at Driver’s Ear
(LpA) ICOMIA 39.94
82.3 dB(A)
Vibration at Tiller (arms)
Less than 2.5 m/s2
(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.
(2) Emission Control Information.
(3) Available as optional kit.
(4) Not supplied in all marketing areas.
(5) Does not include propeller or fuel.
12 - General Information
EMERGENCY STOP SWITCH
If equipped, the emergency stop switch is on the
steering handle. Use of the emergency stop feature
is highly recommended on all boats.
Connect the clip to the emergency stop switch.
Snap the lanyard to a secure place on the operator’s clothing or life vest — not where it might tear
away instead of activating the stop switch. Disconnecting the clip and lanyard will stop the engine and
prevent the boat from becoming a runaway if the
driver moves beyond the range of the lanyard. If the
lanyard is too long, it can be shortened by knotting
or looping it. DO NOT cut or retie the lanyard.
An extra clip is provided — another person can insert it in the stop switch and start the motor in an
emergency.
1
1
1. Extra clip
WARNING
2
1. Emergency stop switch
2. Clip
Avoid knocking or pulling the clip off the
stop switch during normal boating. The
resulting unexpected loss of forward
motion can throw occupants forward, causing injury.
Your emergency stop switch can be effective only when in good working condition.
At each outing, inspect clip and lanyard for
cuts, breaks, or wear. Replace worn or damaged parts.
Keep the lanyard free from obstructions and
entanglements.
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.
General Information - 13
FUEL AND OIL
FUEL
Minimum Octane
Inside the U.S.
WARNING
Gasoline is extremely flammable and highly
explosive under certain conditions. Follow
the instructions in this section explicitly.
Improper handling of fuel could result in
property damage, serious injury, or death.
Always turn off the engine before fueling.
Never permit anyone other than an adult to
refill the fuel tank.
Do not fill the fuel tank all the way to the top,
or fuel may overflow when it expands due to
heating by the sun.
Remove portable fuel tanks from the boat
before fueling.
Outside the U.S.
Always work in a well-ventilated area.
Your outboard is certified to operate on unleaded
automotive gasoline with an octane rating equal to
or higher than that specified in Minimum Octane
chart. When using gasoline that contains MTBE or
alcohol, follow these guidelines:
Using unleaded gasoline that contains methyl tertiary butyl ether (MTBE) is acceptable ONLY if the
MTBE content does not exceed 15% by volume.
Using alcohol-extended fuels is acceptable ONLY if
the alcohol content does not exceed:
• 10% ethanol by volume; or
• 5% methanol with 5% cosolvents by volume
89 RON
Your outboard has been designed to operate using
the above fuels; however, be aware of the following:
The boat’s fuel system may have different requirements regarding the use of alcohol fuels. Refer to
the boat’s Owner Guide.
Alcohol attracts and holds moisture that can cause
corrosion of metallic parts in the fuel system.
Alcohol blended fuel can cause engine performance problems.
IMPORTANT: Always use fresh gasoline. Gasoline
will oxidize and weather; the result is loss of octane,
volatile compounds, and the production of gum and
varnish deposits which can damage the outboard.
Always wipe off any fuel spillage.
Do not smoke, or allow open flames or
sparks, or use electrical devices such as
cellular phones in the vicinity of a fuel leak
or while fueling.
87 (R+M)/2 AKI
WARNING
Leaking fuel is a fire and explosion hazard.
All parts in the fuel system should be
inspected frequently and replaced if signs
of deterioration or leakage are found.
Inspect the fuel system each time you
refuel, each time you remove the engine
cover, and annually.
OIL
Evinrude/Johnson XD25 formula outboard oil is
recommended for your outboard. It contains a
richer additive package than other TC-W3 oils, minimizing carbon build-up and deposits on pistons
and bearing surfaces. It provides 25% greater detergency than minimum TC-W3 requirements.
Evinrude/Johnson brand oils are formulated to give
best engine performance while controlling piston
and combustion chamber deposits, providing superior lubrication, and ensuring maximum spark plug
life.
If Evinrude/Johnson XD25 formula outboard oil is
not available, you must use an NMMA-certified TCW3 oil such as Evinrude/Johnson direct injection oil
or Evinrude/Johnson biodegradable outboard oil.
IMPORTANT: Failure to follow this recommendation could void the engine warranty if a lubricationrelated failure occurs.
14 - Fuel and Oil
ADDITIVES
IMPORTANT: Only use fuel additives approved by
Bombardier for your outboard. Use of other fuel additives can result in poor performance or engine
damage.
Evinrude/Johnson 2+4 fuel conditioner will help
prevent gum and varnish deposits from forming in
fuel system components and will remove moisture
from the fuel system. It can be used continuously
and should be used during any period when your
engine is not being operated on a regular basis. Its
use will reduce spark plug fouling, fuel system icing,
and fuel system component deterioration.
Portable Tank
Above and below 32° F (0°C), add one gallon of fuel. Pour in required amount of oil. Add remaining fuel. Install filler cap and tip tank gently to distribute
oil.
FUEL/OIL RATIO
New Engine
During break-in, you must use a 25:1 (4% oil) fuel/
oil ratio in your fuel tank. Refer to Break-In (10
Hours).
Normal Operation
After break-in, the engine must be operated at a
50:1 (2% oil) fuel/oil ratio.
High Performance
During high performance operation you must use a
25:1 (4% oil) fuel/oil ratio in your fuel tank.
Permanently Installed Tank
Above 32° F (0° C), pour oil slowly with the fuel as
tank is filled. Below 32° F (0° C), add one gallon of
fuel to a separate container. Pour in required
amount of oil. Install filler cap and tip container gently to distribute oil. Slowly pour oil/fuel mixture into
tank with fuel as tank is filled.
MIXING FUEL AND OIL
Use the following chart and these guidelines to mix
oil with the engine’s fuel.
Ratio
50:1
25:1
6 U.S. Gallons
16 fl. oz. oil
32 fl. oz. oil
Fuel
3 U.S. Gallons
8 fl. oz. oil
16 fl. oz. oil
1 Liter
20 ml oil
40 ml oil
Fuel and Oil - 15
FUEL SYSTEMS
WARNING
If your motor is equipped with a quick-disconnect fuel hose, disconnect the fuel hose
from the motor and from the fuel tank when
the motor is not being used for a period of
time. Disconnecting the hose will avert fuel
leaks in the hose or at the engine.
IMPORTANT: Fuel distribution hoses in the boat
must deliver fuel at the rate of flow needed by the
engine. Minimum inside diameter of fuel hoses
must be 5/16 in. (8 mm).
Fuel systems with built-in tanks, particularly those
that include antisiphon valves and filter/primer
units, may have restrictions that will not allow the
engine fuel pump to deliver sufficient fuel under all
conditions. This can result in a loss of performance
and possible engine damage. If a performance
problem exists, see your DEALER.
To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.
BREAK-IN (10 HOURS)
IMPORTANT: Follow this procedure to protect your
new outboard during its initial hours of operation.
Careful break-in allows internal engine components
to “seat” properly, resulting in maximum engine performance.
Failure to carefully follow the break-in procedures
can result in engine damage.
During break-in, you must use extra oil. The fuel/oil
ratio for the first 10 hours of operation must be 25:1
(4% oil). The fuel/oil ratio during normal operation,
after break-in, must be 50:1 (2% oil).
Perform the 10-Hour break-in procedure with the
boat and engine in the water, using an appropriate
propeller.
DO NOT perform break-in using a flushing device.
DO NOT start-up or run the engine out of the water.
DO NOT leave a running engine unattended.
16 - Fuel and Oil
IMPORTANT: Before the first start-up of your
new engine:
• Read Engine Starting, Engine Stopping, and
Shifting and Speed Control.
• Check the gearcase lube level. Refer to Lubrication.
• Perform prelaunch checks of all equipment.
Launch the boat and start the engine according
to the procedures in Engine Starting.
• Verify water pump operation often. Look for a
steady stream of water from the water pump indicator. If the stream of water stops, shut off the engine to prevent damage. Find and correct the
cause, or see your DEALER before you continue.
• Verify shift function by shifting into gear and observing that the boat moves and that the movement is in the same direction as the shifter. Refer
to Shifting and Speed Control.
• Change the RPM often. Avoid holding a throttle
setting longer than 15 minutes.
1. First 10 Minutes of Operation — Operate the
engine in gear at fast idle only.
2. Next 50 Minutes — Operate engine in gear at
various speeds no faster than 3500 RPM.
DO NOT hold a constant throttle setting. Change
engine speed every 15 minutes.
With easy planing boats, use full throttle to quickly
accelerate boat onto plane. Immediately reduce
throttle to one-half as soon as boat is on plane. BE
SURE boat remains on plane at this throttle setting.
3. Second Hour — Use full throttle to accelerate
boat onto plane, then reduce throttle setting to
three-quarters. BE SURE boat remains on plane at
this throttle setting.
At intervals, apply full throttle for periods of one to
two minutes, returning to three-quarters throttle for
a cooling period.
Change engine speed every 15 minutes.
4. Next Eight Hours — Avoid continuous full
throttle operation for extended periods.
Change engine speed every 15 minutes.
DO NOT exceed recommended maximum engine
RPM. Refer to Engine Specifications.
ENGINE STARTING
DANGER
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust
fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide
which, if inhaled, can cause serious brain
damage or death.
WARNING
The engine cover is a machinery guard. DO
NOT operate your outboard with the cover
off unless you are performing maintenance,
and then be careful to keep hands, hair, and
clothing clear of all moving parts. Contact
with moving parts could cause injury.
1
1. RUN position
If you will be using a battery, connect it as instructed
in Battery.
Electric start models can be started manually and
operated without a battery.
WARNING
DANGER
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.
BEFORE START-UP
When not connected to a battery, cover the
positive (+) battery cable’s ring terminal
with the attached boot to prevent the charging system from sparking.
Do not wrap the loose battery cable around
the engine as a way of storing it. Doing so
can restrict steering or damage the cable, or
both. Loop the cable and hang it close to
the engine.
Do not connect electrical equipment to the
engine’s charging system. The connected
equipment and the engine could both be
damaged.
Review and follow Break-In (10 Hours) if the engine is new.
You MUST supply water to the engine before attempting to start it. Engine damage can occur
quickly. Refer to Engine Overheating or Flushing.
Move tilt/run lever to RUN. Be sure the engine is in
normal operating position. Refer to Tilting and Tilt
Support.
1
1. Positive (+) battery cable boot
Engine Starting - 17
Connect the fuel hose to the fuel connector.
If equipped, attach the clip and lanyard assembly to
the emergency stop switch. Snap the lanyard to secure place on your clothing or life vest.
2
1
1
1. Fuel hose connector
2. Fuel connector
1. Emergency stop switch
If equipped, open vent screw on fuel tank’s filler
cap.
Squeeze fuel primer bulb, outlet end up, until firm.
1
Twist the throttle to SHIFT or slower.
2
1
1. SHIFT
1. Fuel tank operable vent
2. Fuel primer bulb
Move the shift lever to NEUTRAL. Refer to Shifting
and Speed Control.
WARNING
Always shift to NEUTRAL before starting
the engine to prevent sudden boat movement, which can cause injury.
18 - Engine Starting
The manual primer has two functions. It primes the
engine for quick cold starting and provides extra
fuel for warm-up.
Twist the throttle grip to START.
1
Rope Start
While seated, grasp the starter handle and pull
slowly until starter engages, then pull hard. Repeat,
if needed, until motor starts. To prevent damage to
starter assembly, allow starter cord to rewind before releasing starter handle. If motor does not
start, refer to Trouble Check Chart.
2
1. START
IMPORTANT: Avoid engine damage. DO NOT run
engine above START in NEUTRAL.
Start-up (Cold Engine)
1
WARNING
Start engine with shift lever in NEUTRAL.
Attempting to manually start the engine
while in gear may damage parts or cause
the start-in-neutral-only feature to become
inoperative.
1. Starter handle
2. NEUTRAL
Electric Start
While seated, press start button to START motor.
Pull primer knob through its full stroke twice and return to the warm-up (color line showing) position.
1
2
1
2
1. START button
2. NEUTRAL
1. Primer knob
2. Color line
Release start button as soon as engine starts. If engine does not start, release button momentarily and
then try again.
Engine Starting - 19
IMPORTANT: Starter motor can be damaged if operated continuously for more than 10 seconds. DO
NOT press start button to START position when engine is running. Starter and flywheel will be damaged.
All Models
Push primer in to RUN (no color line showing) when
motor is sufficiently warmed up.
ENGINE STOPPING
Twist the throttle grip to SHIFT position or slower.
Move shift lever to NEUTRAL.
Press the STOP button until the engine stops running. If equipped, close the vent screw on the fuel
tank’s filler cap.
IMPORTANT: If your outboard does not react normally to this starting procedure or fails to start, refer
to Trouble Check Chart.
After Engine Starts
Check the water pump indicator. A steady stream of
water indicates the water pump is working. If a
steady stream of water from the water pump indicator is not visible, stop the engine. Refer to Engine
Overheating.
1
1. STOP button
To avoid difficulty when restarting, never stop the
engine by running it with the fuel hose disconnected
or otherwise running it out of fuel.
IMPORTANT: To avoid engine damage, after startup, do not exceed one-quarter throttle (less than
2000 RPM) in NEUTRAL for extended periods of
time.
Start-up (Warm Engine)
Follow Cold Engine procedure except warm engines do not normally require priming. If your engine fails to start, then use the primer.
20 - Engine Starting
SHIFTING AND SPEED CONTROL
IMPORTANT: Carefully check the function of all
control and engine systems before leaving the
dock. DO NOT shift the engine into FORWARD or
REVERSE while it is shut OFF.
1
Shifting
With the engine running, twist the throttle grip to
SHIFT or slower.
Move the shift lever briskly and decisively to FORWARD or REVERSE.
2
1. Decrease speed
2. Increase speed
3
2
EMERGENCY STARTING
If the starter cord breaks or the starter fails, your engine can be started using a piece of the starter cord
or a 1/4 in (6 mm) cord about 4 ft. (1.2 m) long.
WARNING
1
1. Shift lever
2. FORWARD
3. REVERSE
WARNING
Do not operate motor in REVERSE with the
tilt/run lever in TILT. Motor may tilt out of the
water, resulting in loss of control.
IMPORTANT: Before moving the shift lever, reduce
throttle to SHIFT speed or slower, then pause until
motor slows to idle speed and boat has slowed.
When using Emergency Starting procedures, the start-in-neutral-only feature is
inoperative. Make sure shift lever is in NEUTRAL position to prevent injuries from
unexpected boat movement when the
engine starts.
The engine cover is a machinery guard. To
prevent injury from moving engine components, keep hands, clothes, and hair clear of
powerhead.
Prevent electric shock by keeping clear of
the ignition coils and spark plug leads when
the motor is being started or is running.
Shock can cause serious personal injury
under certain conditions.
DO NOT turn flywheel by hand. Use starter
cord only.
Speed Control
With the engine running, twist the throttle grip:
• Counterclockwise to increase speed; or
• Clockwise to decrease speed.
Engine Starting - 21
Move tilt/run lever to RUN position. Place motor in
its normal operating position.
Manual Start Models
Remove three screws that secure the manual starter and remove starter assembly from engine.
1
1
1. RUN position
Be sure:
• Engine is in normal operating position.
• Fuel hose primer bulb is firm.
• Shift lever is in NEUTRAL.
• Twist-Grip throttle is at START.
Pull latch and remove engine cover.
1. Screws
Using a screwdriver, compress one of the two locking tabs on the starter lockout cable. At the same
time, pull the cable steadily until that tab clears the
housing. Repeat for the other locking tab. Pull the
lockout cable from the starter housing. Secure the
lockout cable in the lower engine cover, away from
moving engine parts.
1
1. Locking tabs
22 - Engine Starting
Tie a knot in one end of your emergency starter
cord and hook it in the notch on the flywheel. Wind
the cord clockwise around the starter ridge on the
flywheel.
2
1
All Models
Follow the starting procedures in Start-up (Cold
Engine).
While seated, pull hard on emergency starting cord
to start motor. After the motor starts, run it at less
than 2000 RPM in NEUTRAL for two minutes, then
reduce speed to an idle.
Do not attempt to replace manual starter or engine
cover while engine is running. If equipped, snap
emergency stop switch lanyard to a secure place
on your clothing.
Proceed to nearest landing for service.
FUEL ECONOMY
The economy throttle position can save fuel, depending on boat load and hull design. When boat
reaches top speed, throttle back from FULL
SPEED. You will save fuel without a noticeable loss
of speed.
1. Knot
2. NEUTRAL
Electric Start Models
WARNING
DO NOT use jumper cables and a booster
battery to start engine. Do not charge a battery in the boat with an external charger.
Fumes vented during either operation can
lead to an explosion.
Tie a knot in one end of your emergency starter
cord and hook it in the notch on the flywheel. Wind
the cord clockwise around the starter ridge on the
flywheel, making sure the knot clears the starter
pinion.
3
2
1
1. Knot
2. Starter pinion
3. NEUTRAL
Engine Starting - 23
OPERATION
TRAILERING
DANGER
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust
fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide
which, if inhaled, can cause serious brain
damage or death.
DANGER
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.
MOTOR ANGLE ADJUSTMENT
Motor should be perpendicular to the water when
the boat is underway at full speed. This adjustment
can only be determined by water testing the boat.
Set angle adjustment for your normal load.
Place motor in full tilt position. Refer to Tilting and
Tilt Support.
• Move angle adjusting rod.
24 - Operation
Trailer your boat with the motor in a vertical position. If your trailer does not provide adequate road
clearance, the motor can be trailered by using an
accessory trailering bracket.
IMPORTANT: Whenever using an accessory trailering bracket, the motor must be restrained. Bouncing during transport will damage the motor and
boat’s transom. DO NOT use the motor’s tilt support or the shallow-water drive bracket as a trailering bracket.
TILTING AND TILT SUPPORT
WARNING
Your motor has “impact protection” and
“reverse lock” only when the tilt/run lever is
in RUN position. If operated with the tilt/run
lever left in TILT position, the motor could
tilt into the boat suddenly, causing loss of
control or serious injury.
IMPORTANT: Use the tilt grip to tilt your motor; not
the steering handle.
Tilt UP
Tilt DOWN
Move tilt/run lever to TILT position.
Move tilt/run lever to RUN position.
1
1
1. Tilt/run lever – TILT position
1. Tilt/run lever – RUN position
Grasp tilt grip on engine cover and tilt motor to the
full tilt position.
Tilt support will automatically engage.
Grasp tilt grip on engine cover and raise motor
slightly.
Tilt support will automatically disengage. Slowly
lower motor to its normal operating position.
SHALLOW-WATER DRIVE
1
WARNING
When in shallow-water drive, your motor
has no protection from the effects of underwater impact.
Operate your motor in FORWARD and ONLY
at slow speed. The motor can tilt up forcibly
and drop suddenly if it hits an underwater
object or if you shift to REVERSE and apply
throttle. You could lose control.
1. Tilt grip
WARNING
While engine is tilted, leave tilt lever in the
TILT position. When the tilt/run lever is in
the RUN position, tilt support can release
unexpectedly and allow motor to drop.
The motor’s depth in shallow-water drive is controlled by the position of the motor angle adjusting
rod. Relocate the motor angle adjusting rod if necessary. Refer to Motor Angle Adjustment.
Slow the engine and shift to NEUTRAL before engaging or disengaging shallow-water drive.
Operation - 25
Engage
Disengage
Move tilt/run lever to the TILT position.
Move tilt/run lever to the RUN position.
2
1
2
1
1. Tilt/run lever – TILT position
2. NEUTRAL
1. Tilt/run lever – RUN position
2. NEUTRAL
Grasp tilt grip on engine cover and tilt motor halfway.
Shallow-water drive bracket will automatically engage.
Slowly, lower motor until shallow-water drive brackets rests against angle adjusting rod.
Grasp tilt grip on engine cover and tilt motor slightly.
Shallow-water drive bracket will automatically release.
Slowly, lower motor to normal operating position.
IMPORTANT: Check often that water intakes are
completely submerged and the water pump indicator is discharging a steady stream of water.
26 - Operation
PROPELLER SELECTION
1
To select the correct propeller for your boating application, your boat and motor MUST be water tested. See your DEALER for assistance.
Refer to Propeller, before removing or installing
propeller.
2
IMPORTANT: The correct propeller for your boat,
under normal load conditions, will allow the engine
to run near the midpoint of the RPM operating
range at full throttle. Refer to Engine Specifications.
MOORING
You may moor your boat with the motor’s gearcase
out of the water by using its tilt feature. Refer to Tilting and Tilt Support.
FLUSHING
1. Gearcase holes
2. Water intakes
3) Install flushing device and garden hose.
4) Place the shift lever in NEUTRAL with the
propeller removed.
5) Start the water — keep pressure between 20
to 40 psi (140 to 300 kPa).
DANGER
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust
fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide
which, if inhaled, can cause serious brain
damage or death.
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.
1) Place the engine in vertical position in a wellventilated area with good drainage.
2) Cover the two small holes on each side of the
gearcase with heavy tape to make sure
enough water will travel to the powerhead.
Remember to uncover the holes after flushing the engine.
1. Flushing device
2. Water pump indicator
6) Start the engine — run it at idle only and
flush it for at least five minutes. Check the
water pump indicator. A steady stream of water must flow. If it does not, shut OFF the engine and investigate. Refer to Engine
Overheating.
7) Leave the outboard in vertical position long
enough to completely drain the powerhead.
Operation - 27
ENGINE OVERHEATING
IMPORTANT: Do not run your engine — even for a
brief start-up — without supplying water to it. Refer
to Flushing.
While boating, the engine’s water intakes must stay
completely submerged and unobstructed. Observe
proper transom height and trim angle. While the engine is running, the engine’s water pump indicator
must discharge a steady stream of water. Check
the indicator often, especially when operating in
weeds, muddy and debris-laden water, at extreme
trim angles, or in shallow-water drive (if equipped).
1. Water intake screens
2. Water pump indicator
If the engine overheats, the S.L.O.W. (Speed Limiting Overheat Warning) protection system will immediately limit the engine speed to 2000 RPM. If
the engine was running faster than 2000 RPM
when the S.L.O.W. system activated, it will shake
noticeably.
To RESET the S.L.O.W. protection system, the engine must be shut OFF and the cooling temperature
restored.
28 - Operation
IF the S.L.O.W. protection system activates and the
stream from the water pump indicator becomes intermittent or stops, reduce speed to idle and:
• Shift to NEUTRAL;
• SHUT OFF the engine;
• Tilt the motor up;
• Clean the intake screens and four small gearcase
holes of any blockage;
• Clean the water pump indicator of any blockage;
• Lower the motor; and
• Restart the engine and run at idle.
IF cleaning the screens and indicator does not restore the water pump indicator’s steady discharge,
SHUT OFF the engine and do not attempt to operate it. See your DEALER.
IF cleaning the screens and indicator does restore
the water pump indicator’s steady discharge, you
might have to run for two minutes in NEUTRAL to
allow the engine to cool.
IMPORTANT: You must restore cooling to the engine to avoid serious engine damage.
After any overheat, have your DEALER:
Torque the cylinder head screws.
Inspect the water pump for excessive wear or damage.
Inspect the thermostats.
Inspect the engine for leaks.
IMPACT DAMAGE
Your engine has a shock absorption system designed to help withstand damage from impact with
underwater objects at low to moderate speeds.
However, high speed impacts with rigid underwater
objects like pilings or boulders can be beyond the
capability of the absorption system. Such impacts
can result in serious damage to your engine and injury 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
result of rapid deceleration following impacts. When
boating in unfamiliar, shallow or debris-laden waters, seek information on safe boating areas and
navigation hazards from a reliable local source. Reduce your speed and keep a sharp lookout!
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
swivel and stern brackets, steering components,
and components in the area of impact. Also, examine the boat for structural damage. Tighten any
loosened hardware. If the collision occurred in the
water, proceed slowly to harbor. Before boating
again, have your DEALER thoroughly inspect all
components.
WARNING
Failure to inspect for damage could result in
sudden, unexpected component failure,
loss of boat control, and personal injury.
Unrepaired damage could reduce your boat
and engine’s ability to resist future impacts.
STORING
The engine’s shock absorption system does not
work while operating in reverse. If you back into an
object, either in the water or while trailering, your
boat and engine can be seriously damaged.
To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.
If you must tilt the motor to remove it from the water,
lower it and allow the cooling system to drain completely as soon as you clear the launch area.
Between uses, store your motor in a vertical position.
For recommendations on extended periods of storage, refer to Off-Season Storage.
Operation - 29
SPECIAL OPERATING CONDITIONS
High Altitude
Salt Water
If you boat at altitudes above 3000 ft. (900 m), your
engine might benefit from a lower pitched propeller,
different carburetor calibration, or both. See your
DEALER.
Flush the engine internally after use in salt, polluted, or brackish water to help prevent mineral deposits from clogging cooling passages. Refer to
Flushing.
During use in salt or brackish water, additional anodic protection for the boat and outboard may be required.
During long periods of mooring, tilt the gearcase out
of the water — except in freezing temperatures.
Upon removal from salt water, leave it in a vertical
position until its cooling system has drained.
Weedy Water
Weeds block water intakes and cause your outboard to overheat. Weeds on the propeller create
vibration and reduce boat speed.
Run at slow speeds and in REVERSE frequently to
clear weeds from the propeller and water intakes.
Check the water pump indicator often.
If REVERSE operation does not clear away weeds,
SHUT OFF the engine. Remove weeds from propeller area and water intakes before operating at
higher speed.
IMPORTANT: To avoid permanent powerhead
damage, be sure that an engine modified for high
altitude operation is properly identified and returned
to original calibration and propeller size if operated
below 3000 ft. (900 m).
Shallow Water
IMPORTANT: Serious engine damage will occur if
the gearcase is allowed to drag on the waterway
bottom.
Freezing Weather
DURING operation in freezing weather, keep the
gearcase submerged at all times.
Upon removing your motor from the water, leave it
in a vertical position until its cooling system is
drained.
IMPORTANT: Water that has leaked into the gearcase, or remained in the cooling system or other
components can freeze, causing serious engine
damage.
Boat Bottom and Engine External Finish
The condition of your boat’s bottom affects performance. A covering of marine growth reduces
speed. For maximum performance, keep the boat’s
running surface clean by wiping it dry after each use
and washing it occasionally.
After operating your outboard, rinse it with fresh water and wipe it dry. Apply Evinrude/Johnson AntiCorrosion Spray to any surface subject to corrosion, but avoid the anticorrosion anode(s).
Periodically, wash the entire boat and outboard with
soapy water and apply a coat of automotive wax.
Leave the engine cover in place when washing the
outboard.
Submerged Engine
If your engine has been under water, have it serviced immediately upon recovery. If immediate
service is unavailable, resubmerge it in fresh water
to avoid prolonged exposure to the atmosphere.
After submersion, all boat and engine electrical, fuel, and oiling systems must be inspected for signs
of water intrusion. Your DEALER should perform
this service.
Under Tow
Should you require a tow from another boat:
• Shift your engine to NEUTRAL;
• Tilt its gearcase out of the water; and
• Off-load all persons into another boat.
Keep towing speed slower than planing speed.
Auxiliary Engine
When your auxiliary engine is shut OFF, shift it to
NEUTRAL and keep its gearcase out of the water
by tilting it fully or raising the mounting bracket.
30 - Operation
MAINTENANCE
Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine SI (spark ignition) engine repair establishments or individual.
WARNING
Only perform service procedures which are
detailed in this Operator’s Guide. Attempting to perform maintenance or repair on
your outboard if you are not familiar with
the correct service and safety procedures
could cause injury or death.
Tampering with the carburetor to change horsepower or modify emission levels beyond factory
settings or specifications will void the product warranty.
10-HOUR INSPECTION
After 10 hours of operation, your new engine will be
broken in and its mechanical parts will have seated.
At that time, all systems should be checked and any
adjustments needed should be made.
Your DEALER will perform this 10-Hour Inspection
at your request and expense (based on local rates),
according to what your engine needs — refer to Engine Maintenance and Inspection Schedule, 10Hour Inspection for a partial list.
Follow consistent preventive maintenance by having your DEALER check and service your engine
once a year or after each 100 hours of operation,
whichever comes first.
OFF-SEASON STORAGE
You must protect against natural environmental
conditions that can be damaging to an outboard
motor. Temperature and humidity changes while
your outboard motor is not in use can cause corrosion of internal engine parts when they are not protected. Fuel remaining in your fuel tank and in the
engine will oxidize and weather which can result in
loss of octane and can cause gum deposits in the
fuel system. Your warranty does not cover engine
failure caused by these conditions. We strongly recommend that you have your DEALER prepare your
outboard for the off-season.
To do the off-season storage preparations yourself,
gather the supplies and perform the following steps.
2+4 fuel conditioner
Triple-Guard grease
Ultra-HPF gearcase lubricant
Storage Fogging Oil spray can
Stabilize the engine’s fuel supply with 2+4 fuel conditioner 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 engine.
WARNING
Prevent injury from moving engine components. Before starting the engine:
Shift it to NEUTRAL.
Keep hands, clothes, and hair clear of powerhead.
Remove the propeller if you use a flushing
device.
IMPORTANT: Provide water supply to the engine
and start it. Run the engine at idle only.
To run the engine on a flusher, refer to Flushing.
To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.
Maintenance - 31
Storage Fogging Oil — Following instructions on
the can, fog the engine.
PRE-SEASON SERVICE
Ignition, oil, and fuel systems — Check for misplaced leads and damaged or deteriorated parts.
Be sure starter solenoid terminal boot and all connectors are in place.
Remove your outboard from storage and prepare it
for a season of reliable service by performing a general check and a few preventive maintenance procedures.
Examine all loosened or removed hardware and
any steering, throttle, and shift systems. Replace
damaged or missing parts with Evinrude/Johnson
Genuine Parts or equivalent.
Fuel filter — Clean.
Screws, bolts, nuts — Tighten
loose.
any
that
are
Propeller — Remove and examine. If damaged,
see your DEALER. Clean the propeller shaft and lubricate it. Refer to Propeller.
Lubrication — Refer to Lubrication to drain and
refill the gearcase and for lubricating points on the
engine.
Touch up painted surfaces and wax the engine’s
exterior. Store the engine on the boat (or an engine
stand) in a vertical, self-draining position.
IMPORTANT: Never place the gearcase higher
than the powerhead. Any water remaining in the exhaust 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 engine 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 fitting is a quick-disconnect. If not, and the hose is secured 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 accidentally ignite. Close the filler cap vent
screw, if equipped. Be sure the disconnected fuel hose does not drip.
WARNING
Failure to carefully reattach the outboard
and its control systems with factory-specified hardware can result in sudden, unexpected loss of boat control.
With the propeller removed, check the gearcase for
leakage. If leakage is evident, the gearcase seals
should be replaced. See your DEALER.
Anticorrosion anodes — Check condition. Refer
to Anticorrosion Anodes.
Install the propeller unless you will run the engine
on a flusher for your pre-season servicing. If so, install the propeller after you shut OFF the engine
and disconnect the flusher. Refer to Flushing.
Refer to Propeller to install the propeller.
WARNING
Prevent injury from contact with rotating
propeller; remove the propeller before
flushing.
Top off fuel tank with fresh fuel.
Battery — Charge fully and install. Refer to Battery.
Follow Engine Starting and start the engine. Let it
idle while you:
Observe running quality – if poor, refer to Trouble
Check Chart or see your DEALER.
Observe water pump operation. Water must flow
from the water pump indicator in a steady stream. If
it does not, shut OFF the engine and investigate.
Refer to Engine Overheating.
Stop the engine and check the fuel system for
leaks.
WARNING
Failure to check for fuel leakage could allow
a leak to go undetected, resulting in fire or
explosion.
32 - Maintenance
BATTERY
Each outboard needs one battery that is:
• 12-volt, heavy-duty, designated "marine";
• Vented/refillable or maintenance-free; and
• Rated according to the minimum requirements in
Engine Specifications.
Deep-cycle batteries are suitable IF they meet or
exceed the minimum CCA requirements.
Ask your DEALER about your outboard’s requirements before installing longer battery cables, a battery switch or a battery insulator.
Installation
Read and understand the safety information supplied with your battery BEFORE you begin installation.
IMPORTANT: Place the battery in a hold-down
system and in a location that is easily accessible for
frequent checking and recharging.
Place a large-surface star washer over the battery’s
positive (+) post. Stack the RED battery cable from
the motor on the star washer, then install cables
from accessories (if any). Finish the connection
with a hex nut and tighten it firmly with a wrench.
Connect the motor’s BLACK battery cable to the
battery’s negative (–) post in the same manner.
WARNING
Keep the battery connections clean, tight
and insulated to prevent their shorting or
arcing and causing an explosion. If the battery mounting system does not cover the
connections, install covers. Check often to
see that connections stay clean and tight.
1. Large surface star washer
2. Cover
Tighten all connections securely and coat the installation with Triple-Guard grease.
IMPORTANT: DO NOT use wing nuts on battery
connections even if they came with the battery.
Wing nuts can loosen and cause errant warning
signals or electrical system damage.
Service
Before servicing the battery or the outboard, remove both battery cables from the battery, BLACK
(–) cable first. Keep metal objects from contacting
either battery post.
IMPORTANT: Service electrical components only
while the outboard is NOT running. Be careful when
identifying positive and negative battery cables and
posts. If you touch the wrong post with a battery cable, even briefly, the charging system will be damaged.
WARNING
Battery electrolyte is acidic — handle with
care. If electrolyte contacts any part of the
body, immediately flush with water and seek
medical attention.
Maintenance - 33
ADJUSTMENTS
Idle Speed
The idle speed adjusting knob is located at the end
of the steering handle. Before turning the knob, be
sure the throttle is at SLOW and the motor has
reached normal operating temperature:
• Increase idle speed – turn knob clockwise
• Decrease idle speed – turn knob counterclockwise
1
1. Steering friction adjustment screw
WARNING
1
DO NOT overtighten for “hands-off” steering. Reduced steering control could result.
Trim Tab
1. Idle speed adjusting knob
If your engine displays poor running quality at idle,
ask your DEALER to perform the necessary adjustments.
WARNING
Improper trim tab adjustment can cause difficult steering.
Carburetor
High speed fuel calibration is maintained by the
fixed high speed jet in the carburetor. Fixed jets are
not adjustable.
Low speed fuel calibration is set at the factory with
a range of adjustment provided. If your engine displays poor running quality at low speed or idle, ask
your DEALER to perform the necessary adjustments.
Steering Friction
The steering friction was set on your new motor before it left the factory. After the first 10 hours of service, check to see that it is still correct. A slight drag
should be felt when turning the motor. If adjustment
is necessary, turn the adjustment screw:
• Clockwise to increase friction; or
• Counterclockwise to decrease friction.
34 - Maintenance
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.
IMPORTANT: A single trim tab adjustment will relieve steering effort under only one set of speed,
motor angle and load conditions. No single adjustment can relieve steering effort under all speed,
motor angle and load conditions. If the boat pulls to
the left or right when its load is evenly distributed,
adjust the trim tab as follows:
With the motor shut OFF, loosen the trim tab
screw. If the boat pulled to the right, move the rear
of the trim tab slightly to the right. If the boat pulled
to the left, move the rear of the trim tab slightly to
the left.
LUBRICATION
Gearcase
Replace gearcase lubricant after first 10 hours of
operation. Check level and condition of lubricant after next 50 hours of operation. Add lubricant if necessary.
Thereafter, check level and condition of lubricant
every 50 hours. Replace lubricant every 100 hours
of operation or once each season, whichever occurs first. Refill with Ultra-HPF gearcase lubricant.
If not available, Hi-Vis® or other marine gearcase
lube can be used, however, long term durability
may be affected with continued use. See your
DEALER.
Tighten the trim tab screw to a torque of 60 to 85 in.
lbs. (7 to 9 N·m).
Test the boat and, if needed, repeat the procedure
until steering effort is as equal as possible.
High motor installations — The trim tab might
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
the trim tab.
IMPORTANT: The recommended gear lubricants
include special additives for marine applications.
Do not use automotive gear lubricants, 2-stroke or
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 characteristics, see your DEALER. If drained lubricant is in good condition, continue.
3) Place tube of lubricant in drain/fill hole and fill
slowly until lubricant appears at lubricant level hole. See Engine Specifications for gearcase capacity.
4) Install lubricant level plug before removing
tube from drain/fill hole. Drain/fill plug can
then be installed without loss of lubricant.
5) Securely tighten both plugs.
2
3
1
1. Drain/fill plug
2. Lubricant level plug
3. Shift cradle screw – DO NOT REMOVE.
Maintenance - 35
Lubrication Points
Refer to Engine Maintenance and Inspection
Schedule for lubrication frequency and recommended lubricant.
1
2
1
1. Carburetor linkage, starter lockout
1. Throttle linkage
2. Engine cover latch
2
1
1. Starter pinion shaft splines
1
1
1. Tilt tube, clamp screws
2. Tilt lever shaft
1. Shallow-water drive bracket, tilt support, swivel
bracket
1
1. Shift lever shaft
36 - Maintenance
FUEL PUMP FILTER
The fuel filter is located in the motor’s fuel pump. An
authorized Evinrude/Johnson DEALER should service the fuel filter.
WARNING
Prevent excessive fuel spillage by disconnecting fuel hose from motor before disassembly.
The filter is located under the inlet cover on the fuel
pump. To service, proceed as follows:
If portable tank is used, disconnect the fuel hose
from the motor before servicing the filter.
Loosen screw and remove the cover. Do not lose
O-rings.
1
2
3
SPARK PLUGS
WARNING
The ignition system presents a serious
shock hazard. The primary circuit operates
in excess of 250 volts; the secondary circuit
operates in excess of 25,000 volts. Use caution to avoid injury from shock or injury
resulting from your reaction to shock. Do
not handle primary or secondary ignition
components while the engine is cranking or
running.
Inspect spark plugs periodically. Replace if electrodes are badly worn, insulators are cracked, or if
they are badly fouled.
To remove spark plugs, twist and remove all spark
plug leads. Unscrew spark plug from cylinder head.
To install spark plugs, wipe spark plug seats clean
with a clean rag. Install spark plugs finger tight, then
tighten to specified torque. Refer to Engine Specifications.
IMPORTANT: Avoid engine damage by installing
spark plugs into COOL cylinder head and not overtightening.
Before installing the spark plug lead, apply a light
coat of Triple-Guard grease to the ribbed portion of
the spark plug. This will help prevent corrosion between the spring terminal and the spark plug.
1. Cover
2. Filter
3. O-rings
Wash filter with clean solvent; blow dry.
Reinstall filter, keeping lip of filter screen toward
fuel pump body.
Install large O-ring in its groove in the cover and the
small O-ring around center post of pump body.
Replace O-rings if cut or damaged.
Reinstall cover.
Tighten cover screw securely; clean up spilled fuel.
Check for leaks – connect fuel hose to motor and
squeeze primer bulb until firm.
1. Ribbed portion of the spark plug
WARNING
Failure to inspect your work could allow fuel
leakage to go undetected, becoming a fire
or explosion hazard.
Maintenance - 37
PROPELLER
Continue to tighten propeller nut until nut slots and
cotter pin hole are aligned. Install new cotter pin
and bend ends to secure.
WARNING
When servicing the propeller, always shift
the outboard to NEUTRAL position, and
twist and remove all spark plug leads so the
engine cannot be started accidentally.
IMPORTANT: Apply Triple-Guard grease to the entire propeller shaft before installing the propeller. At
least annually, remove the propeller and check for
debris. Clean the shaft and regrease it before reinstalling a propeller.
Installation
Slide thrust washer onto shaft with fish line trap
groove facing forward.
Slide propeller onto shaft, engaging the splines and
seating it on the thrust washer.
Slide spacer onto the shaft and engage the propeller shaft splines.
Wedge a block of wood between the propeller
blade and the antiventilation plate.
1.
2.
3.
4.
Thrust washer
Spacer
Propeller nut
Cotter pin
Remove block of wood. Make sure engine is in
NEUTRAL; give propeller a spin. It must turn freely.
Repair
If your propeller hits a solid object, the impact is partially 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 vibration. Damage to the hub can cause excessive engine RPM with little forward movement.
IMPORTANT: Avoid or limit operation using a damaged 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.
Install propeller nut and tighten to a torque of 120 in.
lbs. (14 N·m).
38 - Maintenance
Fish Line Trap
The thrust bushing contains a built-up groove as a
trap for fish line. Every 15 to 20 hours of operation,
or whenever you suspect the presence of fish line,
remove the propeller and check the trap. Remove
any debris.
ANTICORROSION ANODES
Your motor is equipped with one or more anodes
that protect it from galvanic corrosion. Refer to Features for anode location. Disintegration of the anode is normal and indicates it is working. Check
each anode periodically. Replace anodes smaller
than 2/3 their original size. See your DEALER for
replacements.
1
1. Fish line trap groove
IMPORTANT: Fish line can damage propeller shaft
seals. Damaged seals can allow water to enter the
gearcase, causing internal damage.
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 fasteners, or its mounting surface. Painting will reduce its
corrosion protection.
Maintenance - 39
AC LIGHTING
1
2
3
1. Sleeve
2. Electrical tape covering connection
3. Light bulb
Y – Yellow wire
YG – Yellow/Grey wire
YB – Yellow/Blue wire
Some models have an AC (alternating current)
lighting system for operating lights on a boat. An AC
lighting system is available as an optional kit.
IMPORTANT: Alternating current is generated and
MUST NOT be connected directly to a battery. For
battery charging, install a battery charging kit. See
your DEALER.
Various combinations of light bulbs can be used.
Use 12-volt bulbs of wattage sizes indicated on the
diagram.
Follow the illustration for proper installation of
wires.
40 - Maintenance
TROUBLE CHECK CHART
IMPORTANT: If you are unable to identify or solve the problem, contact your DEALER.
SYMPTOM
POSSIBLE CAUSE
Engine will not start
•
•
•
•
•
•
•
Engine will not idle properly
• Motor angle excessive.
• Spark plugs damaged or incorrect. Refer to Engine Specifications.
• Fuel system contaminated with water or dirt.
• Carburetor mixture out of adjustment.
• Fuel/oil mixture incorrect.
Engine loses power
• Spark plugs damaged or incorrect. Refer to Engine Specifications.
• Fuel filter obstructed.
• Fuel system contaminated with water or dirt.
• Water intakes obstructed and cooling system not operating correctly. Refer to Engine Overheating.
Engine vibrates excessively
•
•
•
•
•
Engine runs, but makes little or
no progress
•
•
•
•
Not following starting instructions. Refer to Engine Starting.
Fuel tank empty.
Fuel hose disconnected, kinked.
Fuel system contaminated with water or dirt.
Fuel filter obstructed.
Cold engine – Engine not primed.
Warm engine – Engine flooded. Disconnect fuel hose at engine,
push in choke or primer, crank engine. If it starts, run until cleared.
If it fails to start, wait a few moments and try again.
• Spark plugs incorrect. Refer to Engine Specifications.
• Spark plugs improperly gapped, carboned, burned or wet.
• Ignition system component failure.
Propeller shaft bent.
Propeller fouled and restricted, blades bent or broken.
Fuel system contaminated with water or dirt.
Engine mount(s) damaged.
S.L.O.W. protection mode activated. Refer to Engine Overheating.
• Carburetor mixture out of adjustment.
• Steering friction screw loose (if so equipped).
Propeller hub loose, slipping.
Propeller blades bent or missing.
Propeller shaft bent.
Propeller fouled and restricted.
Maintenance - 41
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 inspection scheduled to be performed by you and/or by an authorized DEALER. The schedule should be
adjusted 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.
Engine Maintenance and Inspection Schedule
Every 200 Hours
or Biannually
Every 100 Hours
or Annually
Every 50 Hours
or 6 months
10-Hour
Inspection
Description
Engine
Care
Product
Each Use
Frequency
Clamp screws, lubricate (1)
7
Every 60 days / Every 30 in Saltwater
Tilt tube / tilt lever shaft, lubricate (1)
7
Every 60 days / Every 30 in Saltwater
Swivel bracket / tilt support bracket,
lubricate (1)
7
Every 60 days / Every 30 in Saltwater
Shift lever shaft / shallow water drive bracket,
inspect and lubricate (1)
7
Every 60 days / Every 30 in Saltwater
Engine cover latch, lubricate (1)
7
Every 60 days / Every 30 in Saltwater
Throttle and shift linkage, lubricate (1)
7
Every 60 days / Every 30 in Saltwater
Carburetor linkage / starter lockout, inspect
and lubricate (1)
7
Every 60 days / Every 30 in Saltwater
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
Flush cooling system
O
Emergency Start Cord, onboard and inspect
O
Operator’s Guide, onboard
O
Clamp screws, tighten
O
Engine upper and lower motor covers, clean
and wax
O
Operator’s Guide, review
O
Fuel filter inspection, eliminate
contamination
D
Fuel system components, inspect and repair
leaks (2)
D
42 - Maintenance
D
Engine Maintenance and Inspection Schedule
D
D
Thermostat, inspect and verify operation (2)
D
D
Engine to transom mounting hardware, retorque
D
D
Electrical and ignition wires and connections,
inspect
D
D
Gearcase lubricant replace
5
D
D
Powerhead synchronization and linkage,
inspect (2)
7
D
D
Gearcase lubricant, inspect fill level and
condition of lube
5
D
Starter pinion shaft, inspect and lubricate (3)
9
D
Propeller shaft splines, inspect and lubricate
7
Spark plugs, replace (2)
D
D
Decarbonize
10
Driveshaft splines, inspect and lubricate
8
Water pump, inspect and replace
Every 200 Hours
or Biannually
Every 50 Hours
or 6 months
Fastener inspection, tighten loosened
components
Description
Engine
Care
Product
Each Use
10-Hour
Inspection
Every 100 Hours
or Annually
Frequency
D
D
D
(1) Also recommended at 10-Hour Inspection
(2) Emission-related component
(3) Do not use light duty penetrating lubricants
D
Dealer Performed Service
O
Operator Performed Service
4
Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1” multi-purpose lubricant
5
Ultra-HPF gearcase lubricant
6
Power Trim/Tilt Fluid
7
Triple Guard frease
8
Evinrude/Johnson Moly Lube P/N 175356
9
Starter Bendix Lube Only P/N 337016
10
Evinrude/Johnson Engine Tuner
Maintenance - 43
NOTES
44 - Maintenance
Maintenance - 45
INSTALLATION
WARNING
Your engine must not exceed the maximum
horsepower indicated on the boat’s capacity
plate. Such overpowering can cause loss of
control. Contact your DEALER or the boat’s
manufacturer if your boat lacks a capacity
plate.
Transom Height and Shaft Length
The transom height dimension listed in Engine
Specifications is the height of the boat transom
your engine needs. This dimension is measured at
the transom centerline, perpendicular to the bottom
of the boat.
Boats designed for remote-steered engines
might be overpowered by a tiller-steered
engine of the maximum rated horsepower.
Ask your DEALER or boat manufacturer is
you are unsure about your boat’s suitability.
1
Incorrectly matched boat and engine transom heights can cause boat instability and
loss of control. Refer to Transom Height
and Shaft Length.
Prevent lateral movement and possible
engine loss by using the mounting hardware supplied or hardware of sufficient size,
strength, and quality. Refer to Installing the
Engine.
A mounting surface that is damaged or too
thin to support your engine while underway
might fail during operation, causing you to
lose control. Be sure the boat’s transom or
mounting bracket is structurally sound and
between 1 1/2 in. (38 mm) and 2 1/4 in. (57
mm) in thickness.
2
1. Transom height
2. Antiventilation plate
3. Final position – 0 to 2 in. (0 to 51 mm)
Use this procedure to determine whether or not the
boat’s transom height is correct for the engine’s
shaft length:
Lift the engine using the lift grips (NOT the tilt grip
or steering handle) and place it in the center of the
boat’s transom.
1
1. Lift grips
46 - Maintenance
3
1
If equipped, tighten clamp screws by hand, NOT
with tools.
Adjust the motor angle so the antiventilation plate is
parallel with the boat bottom. Refer to Motor Angle
Adjustment.
The resulting position of the antiventilation plate
must be no higher than the boat’s bottom and no
lower than 2 in. (5,1 cm) below it.
If the resulting position of the antiventilation plate is
above or below the 0 to 2 in. (0 to 5,1 cm) range, the
engine shaft length must be changed or the boat’s
transom must be modified.
If you install and operate the engine:
Lower than recommended — Serious powerhead
damage could result from water entry into the lower
engine cover or overloading from an under-revving
propeller at wide open throttle.
Higher than recommended — Serious powerhead
damage could result from inadequate cooling or an
over-revving propeller. Propeller ventilation (slippage) often occurs, resulting in poor boat performance.
On a specialty hull, non-planing hull, or on a boat
with a curved transom, these guidelines might not
apply. See your DEALER for special installation information.
Installing the Engine
WARNING
The outboard must be correctly installed.
Failure to correctly install the outboard
could result in serious injury, death or property damage. We strongly recommend that
your DEALER install your outboard to
ensure proper installation.
IMPORTANT: Follow all directions carefully. The
engine’s warranty will not cover product damage or
failure that results from incorrect engine installation.
WARNING
Even if equipped with clamp screws, your
engine must be bolted to the boat to prevent
it from “working off the transom” during
operation.
Center the engine on the boat’s transom (or mounting bracket) and tighten the clamp screws by hand,
NOT with tools. See your DEALER for an accessory transom plate to protect the boat’s transom.
Maintenance - 47
Bolt your engine to the boat’s transom using the
mounting hardware provided.
2
1
3
1. Clamp screws
2. Transom plate
3. Upper stern bracket holes
After positioning the engine, use the stern brackets
as a template for location and size of holes to drill in
the transom.
48 - Maintenance
The stern bracket has two holes on each side of the
engine. Drill only one hole on each side. Use the
upper holes unless your situation requires using the
lower holes. Be sure to drill at right angles to the
transom.
Apply polysulfide sealant generously behind the
heads and to the shanks of the mounting bolts before inserting them and to the surfaces of washers
that contact the transom. Avoid RTV silicone and
polyurethane sealants as they can be dissolved by
gasoline.
Secure the engine with the mounting hardware.
After 30 minutes of operation, retighten clamp
screws by hand. DO NOT use tools to tighten clamp
screws. Check clamp screws regularly.
WARNING
When replacing bolts, screws, or other fasteners, use Johnson parts or parts of equivalent strength and material.
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 Bombardier 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 division where the outboard was
registered. Please contact your Dealer or Distributor.
Change of address
Change of ownership
Model number
Serial Number
Old address / Previous owner
Last name
First name
M.I.
Address
City
Zip code
State
Country
Phone number
Signature
Date
New address / New owner
Last name
First name
M.I.
Address
City
Zip code
State
Country
Phone number
Signature
Date
000063
Maintenance - 49
50 - Maintenance
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:
Owner of Model No:
Serial No:
(To be completed by customer or selling DEALER)
The DEALER named on this document has instructed me on the operation, maintenance, safety
features and warranty policy, all of which I understand and agree to be bound with. I am also satisfied
with the predelivery set-up and inspection of my Evinrude/Johnson Outboard. I have also received a
copy of the Operator’s Guide.
Signature:
Date:
Maintenance - 51
52 - 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, preoccupation, 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; however, 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.
2004
Operator's Guide
*215476*
40 HORSEPOWER
R, RL
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