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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 Recreational Products Inc. or its affiliates:
Evinrude®
Johnson®
Evinrude®/Johnson® Genuine Parts
2+4® fuel conditioner
Evinrude®/Johnson® 4-Stroke outboard oil
Hi-Vis™ gearcase lubricant
Evinrude®/Johnson® Ultra™ 4-Stroke synthetic blend oil
Triple-Guard® grease
Evinrude®/Johnson® anti-corrosion spray
Ultra-HPF™ gearcase lubricant
99011-95J11-BBD
Contents
GENERAL INFORMATION ................................................................................................... 2
SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2
PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4
BRP LIMITED WARRANTY FOR 2007 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD IN THE UNITED STATES AND CANADA ................................................................................................ 5
BRP LIMITED WARRANTY FOR 2007 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD OUTSIDE THE UNITED STATES AND CANADA ................................................................................... 8
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 9
FEATURES ............................................................................................................................................................... 12
ENGINE SPECIFICATIONS ...................................................................................................................................... 14
EMERGENCY STOP SWITCH .................................................................................................................................. 15
WARNING SIGNAL ................................................................................................................................................... 15
FUEL AND OIL ................................................................................................................... 16
FUEL .........................................................................................................................................................................
OIL .............................................................................................................................................................................
ADDITIVES ................................................................................................................................................................
FUEL SYSTEM ..........................................................................................................................................................
BREAK-IN (10 HOURS) ............................................................................................................................................
16
16
17
17
18
BEFORE START-UP .................................................................................................................................................
ENGINE STOPPING .................................................................................................................................................
SHIFTING AND SPEED CONTROL .........................................................................................................................
EMERGENCY STARTING ........................................................................................................................................
19
22
22
23
MOTOR ANGLE ADJUSTMENT ..............................................................................................................................
TILTING AND TILT SUPPORT .................................................................................................................................
SHALLOW-WATER DRIVE ......................................................................................................................................
MOORING .................................................................................................................................................................
FLUSHING ................................................................................................................................................................
LOW OIL PRESSURE WARNING ............................................................................................................................
OVER-REVOLUTION LIMITING SYSTEM ...............................................................................................................
ENGINE OVERHEATING ..........................................................................................................................................
TRAILERING .............................................................................................................................................................
IMPACT DAMAGE ....................................................................................................................................................
STORING ..................................................................................................................................................................
CARRYING AND TRANSPORTING .........................................................................................................................
SPECIAL OPERATING CONDITIONS .....................................................................................................................
24
24
25
26
26
27
28
28
29
29
29
30
31
ENGINE EMISSIONS INFORMATION ......................................................................................................................
10-HOUR INSPECTION ............................................................................................................................................
OFF-SEASON STORAGE ........................................................................................................................................
PRE-SEASON SERVICE ..........................................................................................................................................
CRANKCASE OIL .....................................................................................................................................................
ADJUSTMENTS ........................................................................................................................................................
LUBRICATION ..........................................................................................................................................................
BREATHER AND FUEL LINE ..................................................................................................................................
SPARK PLUGS .........................................................................................................................................................
PROPELLER .............................................................................................................................................................
ANTICORROSION ANODES ....................................................................................................................................
BONDING WIRES .....................................................................................................................................................
BATTERY ..................................................................................................................................................................
TROUBLE CHECK CHART ......................................................................................................................................
ENGINE MAINTENANCE AND INSPECTION SCHEDULE .....................................................................................
32
33
33
34
35
36
37
38
39
39
40
40
41
42
44
ENGINE STARTING ........................................................................................................... 19
OPERATION ....................................................................................................................... 24
MAINTENANCE .................................................................................................................. 32
INSTALLATION .................................................................................................................. 46
TRANSOM HEIGHT AND SHAFT LENGTH ............................................................................................................ 46
INSTALLING THE ENGINE ...................................................................................................................................... 47
© 2006 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. 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.
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
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.
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 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 injury. 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
Model and Serial Numbers
WARNING
The model and serial numbers appear on a plate attached to the stern bracket or swivel bracket.
Record your outboard’s:
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.
Model Number _________________________________
Serial Number __________________________________
Purchase Date _________________________________
Bombardier Recreational Products (BRP) 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.
Ignition Key Number _____________________________
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 Recreational Products distributor
where the outboard was registered.
Technical Literature
BRP 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.
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.
Declaration of Conformity
• Application of Council Directives:
Directive 2003/44/EC Recreational-Craft
• Relevant Directive(s):
Directive 89/336/CEE Eletromagnetic Compatibility
• Relevant Harmonized Standard(s): As referenced by Council and Relevant Directives
• Product Type:
• Manufacturer:
Marine Outboard 4-Stroke Cycle SI Engine
BRP US Inc.
10101 Science Drive
Sturtevant, WI 53177
Suzuki Motor Corporation
300 Takatsuka-cho
Hamamatsu-shi Shizuoka-ken, 432-8611 Japan
EC Type Certificate:
Engine Model(s)
J25R4SU, BJ25R4SU, J25RL4SU, BJ25RL4SU,
J25TE4SU, BJ25TE4SU, J25TEL4SU, BJ25TL4SU
Exhaust Emissions
Certificate Number
Sound Emissions
Certificate Number
SB5 05 12 54511 022
363-0002-5-TYO
I, the undersigned, hereby declare that the product specified above conforms to the above Directive(s)
and Standard(s).
Fernando Garcia,
Director of Regulatory Affairs and Public Relations
4 - General Information
BRP LIMITED WARRANTY FOR 2007 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD IN THE UNITED STATES AND CANADA
1. SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. ("BRP") warrants its 2007 Johnson ® 4-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:
THIRTY-SIX (36) CONSECUTIVE MONTHS for private, recreational use; or
TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related components
providing input to emission controls (e.g. sensors) are warranted for twenty-four (24) months or two hundred (200) hours of engine use, whichever occurs first. The Product is used commercially when it is used
in connection with any work or employment that generates income, during any part of the warranty period.
The Product is also used commercially when, at any point during the warranty period, it is installed on a
boat that has commercial tags or is licensed for commercial use.
The repair or replacement of parts or the performance of service to Product under this warranty does not
extend the life of this limited warranty beyond its original expiration date. All Evinrude ®/Johnson Genuine
Parts and accessories installed by an authorized dealer at the time of sale, including but not limited to propellers, bear the standard BRP parts and accessories one-year limited warranty.
California residents who purchased or warranty-registered a Product in California should refer to BRP's
California Emissions Control Warranty Statement.
3. CONDITIONS TO HAVE WARRANTY COVERAGE
This warranty coverage is available only on Johnson 4-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 BRP 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 BRP 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. BRP may require proof of proper maintenance prior to authorizing warranty coverage.
General Information - 5
4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE
The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect.
Owner must bring Product, including any defective part therein, to Dealer promptly after the appearance
of the defect, and in any event, within the warranty period, and must provide Dealer with reasonable 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 BRP.
5. WHAT BRP WILL DO
BRP'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 BRP. Such repair
or replacement of parts will be done without charge for parts and labor, at any authorized Dealer. BRP's
responsibility is limited to making the required repairs or replacements of parts with new or BRP-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.
BRP 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 BRP, 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 BRP. BRP 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 BRP 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 BRP limited warranty, BRP 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 BRP Customer Support Services, 250 Sea Horse
Drive, Waukegan, IL, 60085, 1-847-689-7090.
Revision February 2006
General Information - 7
BRP LIMITED WARRANTY FOR 2007 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD OUTSIDE THE UNITED STATES AND CANADA
For a copy of the Limited Warranty, see your Bombardier Recreational Products Inc. (“BRP”) distributor/
dealer authorized to distribute Johnson 4-Stroke products in the country in which the sale occurs.
If further assistance is required, please contact BRP Customer Support Services, 250 Sea Horse Drive,
Waukegan, Illinois, 60085, or the affiliate of BRP where the Product was registered for warranty.
8 - General Information
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
Your Johnson 4-stroke outboard has a special environmental label required by the California Air Resources Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard, describes
the meaning of the star rating system.
The Star Label means Cleaner Marine Engines
The Symbol for Cleaner Marine Engines:
Cleaner Air and Water
For a healthier lifestyle and environment.
Better Fuel Economy
Burns up to 30 to 40 percent less gas and oil than conventional
carbureted two-stroke engines, saving money and resources.
Longer Emission Warranty
Protects consumer for worry free operation.
One Star – Low Emission
The one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet the
Air Resource Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted twostroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.
Two Stars – Very Low Emission
The two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet the
Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star – Low Emission engines.
Three Stars – Ultra Low Emission
The three-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003
exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star
– Low Emission engines.
Four Stars – Super Ultra Low Emission
The four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine
engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also
comply with these standards. Engines meeting these standards have 90% lower emission than One Star
– Low Emission engines.
For more information: Cleaner Watercraft – Get the Facts
1-800-END-SMOG
www.arb.ca.gov
YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION
The California Air Resources Board and BRP are pleased to explain the emission control system warranty
on your Johnson 4-stroke outboard. In California, new outboard engines must be designed, built, and
equipped to meet the State's stringent anti-smog standards. BRP must warrant the emission control system on your outboard for the periods of time listed below provided there has been no abuse, neglect, or
improper maintenance of your outboard.
Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors, and other emissionrelated assemblies.
Where a warrantable condition exists, BRP will repair your outboard at no cost to you including diagnosis,
parts, and labor provided that such work is performed by an authorized BRP dealer.
General Information - 9
Manufacturer's Limited Warranty Coverage
This emission limited warranty covers Johnson 4-stroke outboards certified and produced by BRP for sale
in California, that are originally sold in California to a California resident, or subsequently warranty-registered to a California resident. The BRP U.S. and Canada limited warranty conditions for Johnson 4-stroke
outboards are still applicable to these models with the necessary modifications.
Select emission control parts of your Johnson 4-stroke outboard are warranted from the date of purchase
by the first retail consumer or the date the product is first put to use, whichever occurs first, for a period
of: 4 years, or for 250 hours of use, whichever occurs first.
However, warranty coverage based on the hourly period is only permitted for outboards equipped with the
appropriate hour meters or their equivalent. If any emission-related part on your engine is defective under
warranty, the part will be repaired or replaced by BRP.
Parts covered are:
Component
Thermostat
Carbureted
X
SPFI
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Electrical System
Engine/Ignition Control Module
Spark Plugs, Boots, and/or Wires
Ignition Coils
Wiring Harness
Exhaust System
Engine Holder
Oil Pan
Exhaust Housing
Exhaust Valves
Fuel System
Fuel Pump(s)
Fuel Injectors
Vapor Separator
Carburetor and Internal Parts
Accelerator Pump
Choke System
Crankcase Ventilation System Components
Fuel Lines, Fittings, Clamps
X
X
X
X
X
X
X
Air Induction System
Timing Chain/Belt and Tensioner
Camshaft and Followers
Intake Valves
Electronic Dash Pot System
Throttle Body Assembly
Idle Air Control
Closed Throttle Position Switch
Throttle Linkage
Intake Manifold
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Sensors
Air Temperature Sensor
Cam Position Sensor
Crankshaft Position Sensor
Throttle Position Sensor
Exhaust Temp Sensor
Intake Manifold Pressure Sensor
Cylinder Temperature Sensor
X
X
X
X
X
X
X
X
X
X
X
Gaskets
All Emission Component Gaskets
10 - General Information
The emission warranty covers damage to other engine components that is caused by the failure of a warranted part.
The BRP Operator's Guide provided contains written instructions for the proper maintenance and use of
your outboard. All emission warranty parts are warranted by BRP for the entire warranty period of the outboard, unless the part is scheduled for replacement as required maintenance in the Operator's Guide.
Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by
BRP for the period of time before the first scheduled replacement date for that part. Emission warranty
parts that are scheduled for regular inspection but not regular replacement are warranted by BRP for the
entire warranty period of the outboard. Any emission warranty part repaired or replaced under the terms
of this warranty statement is warranted by BRP for the remainder of the warranty period of the original
part. All parts replaced under this limited warranty become the property of BRP.
Maintenance receipts and records should be transferred to each subsequent owner of the outboard.
Owner's Warranty Responsibilities
As the outboard owner, you are responsible for the performance of the required maintenance listed in your
Operator's Guide. BRP recommends that you retain all receipts covering maintenance on your outboard,
but BRP cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of
all scheduled maintenance.
As the outboard owner, you should however be aware that BRP may deny you warranty coverage if your
outboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
You are responsible for presenting your outboard to an authorized BRP dealer as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.
For any questions regarding your warranty rights and responsibilities or for the name and location of the
nearest authorized BRP dealer, contact BRP Customer Support Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.johnson.com.
General Information - 11
FEATURES
14
Item
Description
Item
8
Description
1
Motor Cover
Clamp Screw
2
Crankcase Oil Drain Screw (Port side)
9
Clamp Bracket
3
Anti-Corrosion Anode
10
Anti-Corrosion Anode
4
Starter Handle
11
Lubricant Level Plug
5
Shift Lever
12
Water Intake
6
Throttle Grip
13
Lubricant Drain/Fill Plug
7
Throttle Tension Screw
14
Water Pump Indicator
12 - General Information
6
Item
1
Description
Starter Button (Electric Start Models)
Item
4
Description
Fuel Connector
2
Choke Knob (Rope Start Models)
5
Emergency Stop Switch/Stop Button
3
Low Oil Pressure Light
6
Fuel Tank
General Information - 13
ENGINE SPECIFICATIONS
25 Models
Displacement
32.8 cu. in. (538 cc)
Engine Type
Four-Cycle, In-line, 2 Cylinder
Full Throttle Operating Range
4700 to 5300 RPM
Power (1)
25 HP (18.6 kw) @ 5000 RPM
Idle RPM in Gear (2)
1000 ± 50
Ignition Timing – Idle (1)
W.O.T.
Not Adjustable
Not Adjustable
Exhaust Emission Control
System: per SAE J1930 (1)
EM (Engine Modification)
Fuel Requirements (1)
87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil
Crankcase – Oil
Capacity
Filter
Evinrude/Johnson ultra 4-Stroke synthetic blend oil
67.6 fl. oz. (2 liters)
See Your Dealer
Warning Signals
Low Oil Pressure
Ignition Features
S.L.O.W.™ (Speed Limiting Overheat Warning)
Starting
R, RL – Rope
TE, TEL / TL – Electric start at engine
Battery, Minimum (3)
500 CCA (620 MCA) with 90 Minutes Reserve Capacity OR
65 Ampere-Hour, 12 Volt
Spark Plug (1)
Torque
Refer to ECI Label
11 to 14 ft. lbs. (15 to 19 N·m)
Gearcase – Lubricant
Capacity
Evinrude/Johnson Ultra-HPF™ gearcase lubricant
14.2 fl. oz. (420 ml)
Propeller
10 1/4 x 12 in. (26 x 30 cm)
Fuel Tank
(3)
Capacity – 6 U.S. gallons (22.7 liters)
Weight (4)
R – 152 lbs. (69 kg)
RL – 159 lbs. (72 kg)
TE – 161 lbs. (73 kg)
TEL – 168 lbs. (76 kg)
Transom Height
R, TE – 14-1/2 to 15 in. (36.8 to 38.1 cm)
RL, TEL / TL – 19-1/2 to 20 in. (49.5 to 50.8 cm)
Sound at Driver’s Ear
(LpA) ICOMIA 39.94
76.2 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) Not supplied in all marketing areas.
(4) Does not include fuel or oil.
14 - General Information
EMERGENCY STOP SWITCH
WARNING SIGNAL
If equipped, the emergency stop switch is on the
tiller 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.
If, during operation, your engine begins vibrating
noticeably and will not exceed 2000 RPM (fast idle),
the low oil pressure warning might have been activated. The engine’s warning system automatically
limits its RPM when crankcase oil pressure falls below what the engine requires.
Oil pressure can fall due to operating conditions
such as rough seas. or it can fall in response to insufficient supply of oil. Once the engine’s warning
system has been activated, you must take appropriate action to restore adequate oil pressure and reset the warning system before the engine can
operate normally.
For information about evaluating low oil pressure
and possible “on-the-water” fixes, refer to Low Oil
Pressure Warning.
1
1. Clip
An extra clip is provided — remove it from the cord
and place it in a safe place on the boat. Another
person can insert the extra clip in the stop switch
and start the motor in an emergency.
WARNING
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 - 15
FUEL AND OIL
FUEL
Minimum Octane
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.
Inside the U.S.
87 (R+M)/2 AKI
Outside the U.S.
90 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.
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
16 - Fuel and Oil
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
Your 4-stroke engine requires oil in the crankcase.
Evinrude/Johnson ultra 4-Stroke synthetic
blend oil is recommended for this outboard engine. It allows for extended oil change intervals and
is best for high load applications. Evinrude/Johnson
ultra 4-Stroke synthetic blend oil delivers ultra viscosity stability, sludge protection, friction reducing
properties, and superior corrosion protection.
If Evinrude/Johnson ultra 4-Stroke synthetic blend
oil is unavailable, you may use Evinrude®/
Johnson® 4-Stroke outboard oil. This oil provides
excellent wear and corrosion resistance under normal operating conditions. For your engine’s oil capacity, refer to Engine Specifications.
IMPORTANT: Failure to follow this recommendation could void the engine warranty if a lubricationrelated failure occurs.
ADDITIVES
IMPORTANT: Only use fuel additives approved by
BRP 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.
FUEL SYSTEM
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.
Fuel and Oil - 17
BREAK-IN (10 HOURS)
IMPORTANT: 4-Stroke outboards are shipped
without oil in the crankcase. You must add oil to
the crankcase before starting the engine for the
first time. It is recommended you add Evinrude/
Johnson 4-Stroke outboard oil. Refer to Changing
the Oil for acceptable substitute lubricants.
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.
High speed operation without sufficient engine
warm-up can result in engine damage.
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 water.
DO NOT leave a running engine unattended.
IMPORTANT: Before the start-up of your new engine:
• Read Engine Starting, Engine Stopping and
Speed Control.
• Check the crankcase oil level. Refer to Crankcase Oil.
• Perform prelaunch checks of all equipment.
• Check the gearcase lubricant level. Refer to Lubrication.
18 - Fuel and Oil
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.
• Change the RPM often. Avoid holding a throttle
setting longer than 15 minutes.
• Check the crankcase oil level often. Add oil if
needed.
First 10 minutes of operation — Run the engine
in gear at idle only.
Balance of First 2 hours of operation — Operate in gear below 3500 RPM or 1/2 throttle only.
With easy planing boats, use full throttle to quickly
accelerate boat onto plane. Immediately reduce
throttle to one-half as soon as the boat is on plane.
BE SURE boat remains on plane at this throttle setting.
Third hour of operation — Run the engine in
gear at various speeds up to 4000 RPM or 3/4 throttle only.
Balance of first 10 hours of operation — Run
the engine in gear at various engine speeds including full throttle, but remain at full throttle no longer
than 5 minutes.
Change the engine speed every 15 minutes.
DO NOT exceed recommended maximum engine
RPM. Refer to Engine Specifications.
ENGINE STARTING
Connect the fuel hose to the fuel connector.
DANGER
1
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. Fuel hose to fuel connector
If equipped, open vent screw on fuel tank’s filler
cap.
Squeeze fuel primer bulb, outlet end up, until firm.
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
Verify crankcase oil level before start-up. Refer to
Crankcase Oil.
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.
Be sure the engine is in the normal operating position. Refer to Tilting and Tilt Support.
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.
1
1. Emergency STOP switch and lanyard
Engine Starting - 19
Move the tilt lock lever to the LOCK position.
IMPORTANT: You may need to use the choke
when restarting a warm engine. If your engine does
not start quickly when warm, follow the procedure
for cold starting.
BEFORE cranking your engine, connect the battery
as instructed in Battery.
WARNING
Do not connect electrical equipment to the
engine’s charging system. The connected
equipment and the engine could both be
damaged.
1
1. Tilt lock lever in LOCK position
Move the shift lever to NEUTRAL.
1
While seated, grasp the starter handle and pull
slowly until the starter engages, then pull hard. Allow the starter cord to rewind slowly.
If your engine doesn’t start after three pulls, push
the choke knob in and repeat the starting procedure. Refer to Trouble Check Chart, if necessary.
2
1. NEUTRAL
1
WARNING
Always shift to NEUTRAL before starting
the engine to prevent sudden boat movement, which can cause injury.
Rope Start Models
Start-up (Cold Engine)
Pull the choke knob fully out. Align the arrow mark
on the throttle grip with the cold start-up position.
Start-up (Warm Engine)
Align the arrow mark on the throttle grip with the
START position. Do not use the choke.
1
1.
2.
3.
4.
Choke knob
Throttle grip
Start position - Engine cold
Start position - Engine warm
20 - Engine Starting
1. Starter handle
2. NEUTRAL
Electric Start Models
Start-up
Align the arrow mark on the throttle grip with the
START position.
IMPORTANT: If motor is operated without a battery, DO NOT connect any electrical equipment to
motor’s charging system as electrical damage
could result.
While seated, press start button to START motor.
Crank the engine no longer than 10 seconds.
1
1
22
2
1. Start position
2. Throttle grip
BEFORE cranking your engine, connect the battery
as instructed in Battery.
The motor can be started manually, and operated
without a battery.
WARNING
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.
1. Start button
2. NEUTRAL
IMPORTANT: The starter motor can be damaged if
operated continuously for more than 10 seconds.
Release start button as soon as engine starts. If engine does not start, release button momentarily and
then try again.
DO NOT press start button when the engine is running. Starter and flywheel will be damaged.
If your outboard does not react normally to this
starting procedure or it fails to start, refer to Trouble
Check Chart.
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.
Engine Starting - 21
After Engine Starts - All Models
Gradually, push the choke in after the engine is
warm.
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.
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.
Shifting
With the engine running, twist the throttle grip to
shift position or slower.
Move the shift lever briskly and completely FORWARD or REVERSE.
1
1
2
1. Water pump indicator
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.
1
1. REVERSE
2. FORWARD
Position NEUTRAL by moving the shift lever to the
center position.
Before shifting into NEUTRAL while boating, twist
the throttle grip to SHIFT position or slower, then
wait until the engine slows to idle and the boat
slows.
WARNING
2
1. NEUTRAL
2. Emergency stop switch/Stop button
Do not operate motor in REVERSE with the
tilt lock lever in RELEASE position. Motor
may tilt out of the water, resulting in loss of
control.
Speed Control
With the engine running, twist the throttle grip:
• Counterclockwise to increase speed
• Clockwise to decrease speed
1. Increase speed
2. Decrease speed
22 - Engine Starting
EMERGENCY STARTING
Remove the cable from the manual starter.
1
WARNING
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.
1. Cable
Remove the three screws securing the manual
starter (with flywheel cover) in place. Lift off the
manual starter and flywheel cover.
DO NOT turn flywheel by hand. Use starter
cord only.
Move the shift lever to NEUTRAL.
1
1. NEUTRAL
Tie a knot in one end of the emergency starter cord.
Thread the small bar from the tools kit halfway
through one knot so it forms a handle.
Connect clip to the emergency stop switch/stop button.
Place knot of starter cord in notch on flywheel pulley. Wrap cord around pulley clockwise.
Follow the starting procedure in Engine Starting.
While seated, pull hard on emergency starting cord
quickly and completely. Repeat, if necessary.
Remove the engine cover.
Disconnect the breather hose from the silencer cover. Loosen the outlet tube clamp screw.
1
2
1
1. NEUTRAL
1. Breather hose
2. Screw
After starting, run the engine in NEUTRAL with the
throttle at the START position 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, attach emergency stop switch’s lanyard to a secure
place on your clothing.
Proceed to nearest harbor immediately for service.
Engine Starting - 23
OPERATION
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.
TILTING AND TILT SUPPORT
IMPORTANT: Use the tilt grip to tilt your motor. Do
not use the tiller handle to raise or lower the motor.
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.
Tilt UP
Move tilt/run lever to TILT position.
MOTOR ANGLE ADJUSTMENT
The 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 as shown at the top of the
page.
24 - Operation
1
1. Tilt lock lever in TILT position
Grasp tilt grip on engine cover and tilt motor to the
full tilt position.
Pull down the tilt lever to engage tilt support.
1
Grasp tilt grip on engine cover and raise motor
slightly.
Pull up the tilt lever to disengage tilt support.
1
2
2
1. Tilt grip
2. Tilt lever
1. Tilt grip
2. Tilt lever
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.
Tilt DOWN
Move tilt/run lever to RUN position.
Slowly lower motor to its normal operating position.
SHALLOW-WATER DRIVE
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
1. Tilt/run lever – RUN position
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
FLUSHING
Engage
Move tilt/run lever to the TILT position.
DANGER
2
1
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.
1. Tilt/run lever – TILT 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.
IMPORTANT: Check often that water intakes are
completely submerged and the water pump indicator is discharging a steady stream of water.
Disengage
Move tilt/run lever to the RUN position.
WARNING
Prevent injury from contact with rotating
propeller; remove the propeller before
flushing.
Outboard — Running
1) Place the engine in vertical position in a wellventilated area with good drainage.
2) Install flushing device and garden hose.
3) Cover the water intake hole with tape.
2
1
1
1. Tilt/run lever – RUN position
2. NEUTRAL
Grasp tilt grip on engine cover and tilt motor slightly.
Shallow-water drive bracket will automatically release.
Slowly, lower motor to normal operating position.
MOORING
You may moor your boat with the motor’s gearcase
out of the water by using its tilt feature. Depending
on the model, refer to Tilting and Tilt Support.
26 - Operation
1. Tape
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).
3) Start the water — keep pressure between 20
to 40 psi (140 to 300 kPa). Flush the engine
for five minutes.
4) Turn off the water, remove the hose and connector (if used) and reinstall flushing plug.
5) Leave the outboard in vertical position long
enough to completely drain the powerhead.
LOW OIL PRESSURE WARNING
1
Should crankcase oil pressure drop to a dangerously low level during engine operation, the low oil
pressure light will come on.
1. Flushing device
1
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.
1. Low oil pressure light
1
1. Water pump indicator
7) Leave the outboard in vertical position long
enough to completely drain the powerhead.
Outboard — Not Running
1) Remove the plug from the flushing port.
1
1. Flushing plug
2) Install flushing device and garden hose with
threads matched to flushing port (thread:
0.75 – 11.5 NHR (ANSI)).
If the low oil pressure light is on, the engine speed
will not exceed 2000 RPM (FAST idle).
If, during operation, your engine slows itself to fast
idle and will not exceed that pace, shut OFF the engine.
If tilted, place the engine in vertical position.
Check the oil level on the dipstick and add oil, if
needed. Refer to Crankcase Oil and Engine
Specifications.
Examine the oil fill cap and drain screw for evidence
of oil leakage and make sure they are tight.
If the dipstick shows the oil level is okay, leave the
engine upright and shut off for ten minutes, then
start it. If the engine still limits itself to about 2000
RPM, see your Dealer.
Reset - After oil pressure has been restored, operate the engine below 1500 RPM to reset the
warning system for normal operation.
The light will come on for a few seconds after the
engine starts. This verifies the warning system is
working.
If the light does not come on, stop the engine and
see your Dealer.
If the light stays on, check the engine oil level and
add oil if necessary.
If the oil level is correct, see your Dealer.
IMPORTANT: If you operate the engine with this
light on, severe engine damage can result. Do not
rely on the low oil pressure light to indicate the need
to add oil. Be sure to periodically check the engine
oil level. If the oil level is low, severe engine damage can result.
Operation - 27
OVER-REVOLUTION LIMITING SYSTEM
This system is activated when engine speed exceeds maximum recommended speed for more
than 10 seconds.
If this system activates, engine speed will automatically be reduced to approximately 3000 RPM.
This system must be reset by moving the throttle to
the idle position for about one second to restore full
engine operation.
IMPORTANT: The Over-Revolution Limiting System will not be activated at recommended maximum throttle unless propeller pitch is insufficient or
other factors (like “over-trimming” or “ventilation”)
prevail.
If the system activates for no apparent reason, see
your Dealer.
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 intake 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
1. Water pump indicator
28 - Operation
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.
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.
TRAILERING
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. See your Dealer.
DO NOT use the tilt support when trailering.
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.
IMPORTANT: Whenever using an accessory trailering bracket, the motor must be restrained. Bouncing during transport will damage the motor and
boat’s transom.
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.
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!
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
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
CARRYING AND TRANSPORTING
If you will be laying the engine down, minimize the
potential for fuel spillage by letting it run “out of gas”
before you remove it from the boat. Disconnect the
fuel hose at the engine while it is still running. Let it
run until it quits.
With the motor tilted up, loosen the carburetor drain
screw and drain the gasoline into a suitable container. After draining, retighten the drain screw and
tilt down the motor.
WARNING
Use a proper, safe container to store any
gasoline drained from the outboard motor.
Drain the crankcase oil from the engine. Refer to
Crankcase Oil.
After removing the engine from the boat, position it
upright until the cooling system stops draining.
Keep the powerhead higher than the gearcase at all
times, or any water remaining in exhaust passages
could travel to the cylinders and cause serious
damage.
IMPORTANT: Do not rest the engine before the engine oil has drained, as oil may enter the cylinder
from the sump or outer casings may be damaged.
IMPORTANT: Do not rest the engine before the
cooling water has drained completely, as water
may enter the cylinder through the exhaust port and
cause problems.
Raise the tiller handle and rest it on a padded surface on its port side. Protect the engine cover from
damage.
1
1. Carburetor drain screw
30 - Operation
IMPORTANT: Do not let the gearcase of the outboard sit higher than the powerhead during transporting or storing. Water may drain into the
powerhead, causing damage to the engine.
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. Your
outboard has a built-in flushing port to facilitate
flushing. 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
Submerged Engine
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.
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.
Operation - 31
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.
ENGINE EMISSIONS INFORMATION
Manufacturer’s Responsibility
Beginning with 1999 model year engines, manufacturers of marine engines must determine the exhaust emission levels for each engine horsepower
family and certify these engines with the United
States of America Environmental Protection Agency (EPA). An emissions control information label,
showing emission levels and engine specifications,
must be placed on each engine at the time of manufacture.
Dealer’s Responsibility
When performing service on all Johnson outboards
that carry an emissions control information label,
adjustments must be kept within published factory
specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed certification standards.
Dealers are not to modify the engine in any manner
that would alter the horsepower or allow emission
levels to exceed their predetermined factory specifications.
Exceptions include manufacturer’s prescribed
changes, such as altitude adjustments.
EPA Emission Regulations
All new 2002 and more recent Johnson outboards
manufactured by BRP are certified to the EPA as
conforming to the requirements of the regulations
for the control of air pollution from new watercraft
marine spark ignition engines. This certification is
contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly
followed and, whenever practicable, returned to the
original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the
EPA requirements on exhaust emissions for marine
products. For more detailed information on this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs
Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs
Group (6403J)
501 3rd. St. NW
Washington, DC 20001
Owner Responsibility
EPA INTERNET WEB SITE:
The owner/operator is required to have engine
maintenance performed to maintain emission levels
within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone to, modify the engine in any manner that
would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.
Tampering with the carburetor to change horsepower or modify emission levels beyond factory
settings or specifications will void the product warranty.
www.epa.gov
32 - Maintenance
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.
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
Evinrude/Johnson ultra 4-Stroke synthetic
blend oil
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 a water supply to the engine
and start it. Run the engine at idle only.
To run the engine on a flusher, refer to Flushing.
Oil — Start the engine and run it at least five minutes to warm the crankcase oil.
Stop the engine and drain the crankcase while the
engine is warm. Refill it with Evinrude/Johnson ultra
4-Stroke synthetic blend oil. Refer to Crankcase
Oil. Restart the engine and run it for a few minutes
to circulate the fresh oil.
IMPORTANT: It is very important that the bearing
surfaces be coated with clean oil before entering a
period of storage, so be sure you run the engine after changing the oil.
Stop the engine.
Spark Plugs — Remove and examine them.
Clean or discard them, if necessary. Refer to Spark
Plugs.
Spray Evinrude/Johnson Storage Fogging Oil into
the spark plug holes.
Install spark plugs; tighten to specifications in
Spark Plugs.
Crank the engine for a short burst to distribute the
fogging oil and to drain the water from the water
pump.
Fuel filter(s) — Clean or change.
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.
Maintenance - 33
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.
If you cannot store the engine in the recommended
vertical position, be sure the cooling system is
drained completely.
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.
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.
PRE-SEASON SERVICE
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.
34 - Maintenance
WARNING
Failure to carefully reattach the outboard
and its control systems with factory-specified hardware can result in sudden, unexpected loss of boat control.
Engine Oil — Check the engine oil level. Refer to
Crankcase Oil.
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 accidental contact with a rotating
propeller; always remove it when using a
flusher to run the engine.
Top off fuel tank with fresh fuel.
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.
CRANKCASE OIL
Changing the Oil
Initial Fill
IMPORTANT: 4-Stroke outboards are shipped
without oil in the crankcase. You must add oil to
the crankcase before starting the engine for the
first time. It is recommended you add Evinrude/
Johnson 4-Stroke outboard oil. Refer to Changing
the Oil for acceptable substitute lubricants.
BEFORE filling the crankcase for the first time, be
sure it is empty by checking the dipstick. Refer to
Checking.
After the first 10 hours of operation, replace the
break-in lubricant with Evinrude/Johnson ultra 4Stroke synthetic blend oil. Refer to 10-Hour Inspection.
Refer to Engine Maintenance and Inspection
Schedule for frequency.
After the first 10 hours of operation, replace the
break-in lubricant with Evinrude/Johnson ultra 4Stroke synthetic blend oil. Refer to 10-Hour Inspection.
If Evinrude/Johnson ultra 4-Stroke synthetic blend
oil is temporarily unavailable, you may use
Evinrude/Johnson 4-Stroke outboard oil or an
equivalent FC-W-approved 10W-40 or 10W-50 oil.
Drain (or siphon) the old oil after running the engine
to warm it. Warm oil flows more quickly and completely, containing more suspended sludge than
cold oil. If you change the oil only once a season,
time the work so the engine contains clean oil during storage.
CAUTION
Checking
Check the oil level when the engine is cold to ensure an accurate reading.
1) Place the engine in a vertical position and remove the upper engine cover.
2) Remove the oil fill cap and dipstick, wipe it
clean, and install it.
3) Remove the dipstick again and locate the line
of oil. If the line of oil is not between the ADD
and the FULL marks, you must add or remove oil as indicated.
Used motor oil may be harmful. Avoid prolonged and repeated skin contact. Wash
affected skin with soap and water.
1) Place the engine in a vertical position and remove the upper engine cover.
2) Unscrew and remove the oil fill cap and dipstick.
3
1
2
1. Oil fill cap and dipstick
2. Add
3. Full
1
1. Oil fill cap and dipstick
4) Securely install the oil fill cap and dipstick and
wipe up any spilled oil.
IMPORTANT: Operating the engine with too much
or too little oil in the crankcase will damage it.
Maintenance - 35
3) Hold a suitable container under the oil drain
screw. Remove the screw and drain the reservior. Before you reinstall the screw, replace the gasket with a new one. Reinstall the
screw and tighten it securely.
ADJUSTMENTS
Throttle Friction
Adjust until a slight drag is felt when accelerating or
decelerating only. DO NOT overtighten.
1
1
1.
Oil drain screw
1. Throttle friction screw
4) Pour the recommended oil into the oil fill until
it reaches the upper mark on the dipstick. Refer to Engine Specifications for crankcase
capacity.
5) Replace the oil fill cap and clean any spilled
oil off the engine and your skin.
6) Reinstall the upper cover.
7) Supply water to the cooling system and run
the engine at idle to check for leaks, especially around the oil filter, drain screw and oil fill
cap. Correct any problems.
8) Stop the engine and recheck crankcase oil
level using the dipstick. Add oil as indicated.
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
• Counterclockwise to decrease friction
For more adjustment, use the steering friction lever.
Move the lever:
• Left to increase friction
• Right to decrease friction
3
1
1
2
1. Oil fill cap and dipstick
2. Add
3. Full
Dispose of used oil in a reasonable manner following all local regulations.
2
1. Steering friction screw
2. Steering friction lever
IMPORTANT: Do not apply any grease or lubricant
to the pivot point of the steering friction lever.
WARNING
DO NOT overtighten for “hands-off” steering. Reduced steering control could result.
36 - Maintenance
LUBRICATION
5) Securely tighten both plugs.
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.
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.
2
1
1. Drain/fill plug
2. Lubricant level plug
IMPORTANT: To avoid insufficient injection of lubricant, check the gear oil level 10 minutes after filling. If the oil level is low, slowly inject the lubricant
up to the correct level.
Maintenance - 37
BREATHER AND FUEL LINE
Lubrication Points
Refer to Engine Maintenance and Inspection
Schedule for lubrication frequency and recommended lubricant.
Inspect the breather and fuel line for leaks, cracks,
swelling, or other damage. If the breather and fuel
line are damaged in any way, they must be replaced. See your Dealer.
1
2
2
1
1. Swivel bracket
2. Clamp screws
1. Breather line
2. Fuel line
WARNING
Steering bracket
38 - Maintenance
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.
SPARK PLUGS
PROPELLER
WARNING
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.
To avoid accidental starting of engine while
changing propellers, twist and remove all
spark plug leads.
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.
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
Place the stopper on the shaft.
Align the propeller with the propeller shaft splines
and slide the propeller onto the shaft.
Place the spacer and washer on the shaft.
Install propeller nut and tighten to a torque of 21 23 ft. lbs. (29 - 31 N·m)
Align grooves in propeller nut with hole in propeller
shaft. Insert the cotter pin and bend its ends over to
lock in place.
4
6
5
1. Ribbed portion of the spark plug
1.
2.
3.
4.
5.
6.
3
2
1
Stopper
Propeller
Spacer
Washer
Propeller nut
Cotter pin
Maintenance - 39
Repair
BONDING WIRES
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.
Bonding wires are used to electrically connect the
engine components so they exist in a common
ground circuit. This allows them to be protected
against electrolysis by the anodes. These wires and
their terminals should be checked periodically to be
sure they have not been damaged.
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.
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.
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.
40 - Maintenance
BATTERY
Each outboard needs one battery that is:
12-volt, heavy-duty, designated "marine"
Vented/refillable or maintenance-free
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 - 41
TROUBLE CHECK CHART
IMPORTANT: If you are unable to identify or solve the problem, contact your Dealer.
SYMPTOM
POSSIBLE CAUSE
Starter motor will not operate
• Shift handle not in NEUTRAL.
• Battery and electrical connections loose or corroded.
• Battery Selector Switch OFF.
Engine will not start
• Not following starting instructions. Refer to Engine Starting section.
• Fuel tank empty.
• Fuel hose disconnected, kinked.
• Fuel system contaminated with water or dirt.
• Fuel filter obstructed.
• COLD ENGINE: Engine not choked
• 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.
Engine will not idle properly
• Motor angle excessive.
• Spark plugs damaged or incorrect. Refer to Engine Specifications.
• Fuel system contaminated with water or dirt.
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.
• Oil pressure very low. Refer to Low Oil Pressure Warning.
Engine vibrates excessively
•
•
•
•
•
Propeller shaft bent.
Propeller fouled and restricted, blades bent or broken.
Fuel system contaminated with water or dirt.
Engine mount(s) damaged.
Steering friction screw loose.
Engine runs, but makes little or
no progress
•
•
•
•
Propeller hub loose, slipping.
Propeller blades bent or missing.
Propeller shaft bent.
Propeller fouled and restricted.
42 - Maintenance
NOTES
Maintenance - 43
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
Swivel bracket, inspect and lubricate (1)
6
Every 60 days / Every 30 in Saltwater
Throttle linkage, inspect and lubricate (1)
6
Every 60 days / Every 30 in Saltwater
Clamp screws, lubricate (1)
6
Every 60 days / Every 30 in Saltwater
Steering bracket, lubricate (1)
6
Every 60 days / Every 30 in Saltwater
Lubrication and corrosion protection for metallic
components
4
Every 60 days / Every 30 in Saltwater
Battery connections and condition, verify
6
O
D
Anticorrosion anodes and bonding wires, verify
operation
O
D
Water intake screens, verify condition
O
D
Overboard water pump indicator, verify operation
O
D
Steering friction check, adjust/tighten
O
D
Throttle and shift operation, verify function
O
D
Emergency stop circuit and lanyard, verify function
O
D
Crankcase oil level, check
O
D
Flush cooling system
O
Clamp screws, tighten
O
Fuel components, inspect and repair leaks (2)
D
D
Fastener inspection, tighten loosened components
D
D
Thermostat, inspect and verify operation (2)
D
D
Engine to transom mounting hardware, re-torque
D
D
Electrical and ignition wires and connections, inspect
D
D
Gearcase lubricant replace
5
D
D
Powerhead synchronization and linkage, inspect (2)
6
D
Engine upper and lower motor covers, clean and wax
Gearcase lubricant, inspect fill level and condition of
lube
D
O
5
D
(3)
8
D
Propeller shaft splines, inspect and lubricate
6
Starter pinion shaft, inspect and lubricate
Spark plugs, replace (2)
44 - Maintenance
D
D
Every 200 Hours
or Biannually
Every 100 Hours
or Annually
Every 50 Hours
or 6 months
10-Hour
Inspection
Engine Care
Product
Description
Each Use
Frequency
Engine Maintenance and Inspection Schedule
Decarbonize
9
Every 200 Hours
or Biannually
Every 100 Hours
or Annually
Every 50 Hours
or 6 months
Engine Care
Product
10-Hour
Inspection
Description
Each Use
Frequency
D
Breather and fuel lines, replace
D
Valve tappet clearance, inspect (2)
D
Crankcase oil, replace (4)
10
Oil filter, replace
Driveshaft splines, inspect and lubricate
D
D
D
D
D
7
D
Water pump, inspect and replace
D
Fuel filter, replace
D
Carburetor, inspect
D
Ignition timing, check
D
Operator’s Guide, onboard
O
Operator’s Guide, review
Timing belt, inspect
O
Replace every 4 years
O
(1) Also recommended at 10-Hour Inspection
(2) Emission-related component
(3) Do not use light duty penetrating lubricants
(4) Replace every 100 hours or annually if Evinrude/Johnson ultra 4-Stroke synthetic blend oil is not used
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
Triple-Guard grease
7
Evinrude/Johnson Moly Lube™ P/N 175356
8
Starter Bendix Lube Only P/N 337016
9
Evinrude/Johnson Engine Tuner
10
Evinrude/Johnson ultra 4-Stroke synthetic blend oil
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.
Use this procedure to determine whether or not the
boat’s transom height is correct for the engine’s
shaft length:
Set the motor on the boat’s transom and adjust the
angle so the anti-ventilation plate is parallel with the
boat bottom. Refer to Motor Angle Adjustment.
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 if you
are unsure about your boat’s suitability.
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 5/8 in. (41 mm) and 2 3/4 in. (70
mm) in thickness.
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.
1. Transom Height
2. Anti-ventilation Plate
3. Final position - 0 to 1 in. (0 to 25 mm)
46 - Installation
The resulting position of the anti-ventilation plate
must be 0 to 1 in. (0 to 25 mm) below the boat’s bottom.
IMPORTANT: If the anti-ventilation plate falls outside the 0 to 1 in. (0 to 25 mm) range, the installation is not considered normal. The motor shaft
length must be changed or the boat’s transom must
be modified.
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
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.
2
Apply a good waterproof caulk 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 positioned as shown.
After 30 minutes of operation, retighten clamp
screws by hand. DO NOT use tools to tighten clamp
screws. Check clamp screws regularly.
WARNING
1
When replacing bolts, screws, and other
fasteners, use Evinrude/Johnson Genuine
Parts or parts of equivalent strength and
material.
1. Clamp screws
2. Accessory transom plate
Bolt your engine to the boat’s transom using 12 mm
bolts, washers, lock washers, and nuts.
After positioning the engine, use the stern brackets
as a template for location and size of holes to drill in
the transom.
Drill two holes of the proper size through the transom. Be sure to drill holes at right angles to the transom.
Installation - 47
48 - Installation
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 BRP will be in a position to contact you if correction to your outboard becomes necessary.
Outside the U.S. and Canada, this card should be sent to the Bombardier Recreational Products division
where the outboard was registered. Please contact your Dealer or Distributor.
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
Installation - 49
Bombardier Recreational Products
50 - Installation
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:
Installation - 51
52 - Installation
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 and cooperation toward essential information contained in this
Guide will build good judgment when boating. Always be alert and careful; a good foundation
for safety.
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