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7 - BRP -- Operator`s Guides

1. Clean or change Ignition oil and fuel systems Check for mis placed leads and damaged or deteriorated parts Be sure starter solenoid terminal boot and all con nectors are in place Maintenance 35 Screws bolts nuts Tighten that are loose any Propeller Remove and examine If damaged see your Dealer Clean the propeller shaft and lubri cate 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 ex haust passages can run into the cylinders and cause serious damage If you remove an installed engine examine all hardware you loosened or removed from the en gine and its steering throttle and shift systems Replace damaged or missing parts with Evinrude Johnson Genuine Parts or equivalent Portable fuel tank Disconnect the hose from the tank Remove the hose from the engine if the fit ting is a quick disconnect If not and the hose is se cured to the engine leave it connected Secure the hose to protect it WARNING VAN Store fuel tanks in a well
2. 4 Clamp Bracket 10 Engine Oil Drain Plug 5 Angle Adjustment Rod 11 Water Pump Indicator 6 Lubricant Level Plug 12 General Information RE Br 1 6 drc24502a 1 7 Item Description Item Description 12 Anti Ventilation Plate 16 Fuel Tank 13 Fuel Connector 17 Remote Control 1 14 Low Oil Pressure Light 18 Emergency Stop Switch Lanyard and Clip 15 Choke Knob 1 Not supplied in all marketing areas General Information 13 ENGINE SPECIFICATIONS 9 9 Models Displacement 18 4 cu in 302 cc Engine Type Four Cycle In line 2 Cylinder Full Throttle Operating Range 9 9 4500 to 5500 RPM Power 1 9 9 9 9 HP 7 3 kw 5000 RPM Idle RPM in Gear 1000 50 Ignition Timing Idle W O T Not Adjustable Not Adjustable Exhaust Emission Control System per SAE J1930 EM Engine Modification Fuel Requirements 7 87 Pump Posted AKI 90 RON Refer to Fuel and Oil Crankcase Oil Evinrude Johnson Ultra TM 4 Stroke synthetic blend oil Capacity 33 fl oz 1 liter Filter See Your Dealer Warning Signals Low Oil Pressure Starting Remote Electric Battery Minimum 360 CCA 465 MCA with 90 Minutes Reserve Capacity OR 50 Ampere Hour 12 Volt Spark Plug Torque Refer to ECI Label 11 to 14 ft Ibs 15 to 19 N m Gearcase Lubricant Evinrude Johnso
3. After the first 10 hours of ser vice 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 e Counterclockwise to decrease friction Additionally the steering tension lever can be ad justed Turn the lever Left to increase friction Right to decrease friction DO NOT apply grease to circled area 1 Steering friction screw 2 Steering tension lever WARNING DO NOT overtighten for hands off steer ing Reduced steering control could result 38 Maintenance LUBRICATION Gearcase Replace gearcase lubricant after first 10 hours of operation Check level and condition of lubricant af ter next 50 hours of operation Add lubricant if nec essary Thereafter check level and condition of lubricant every 50 hours Replace lubricant every 100 hours of operation or once each season whichever oc curs 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 Deal er 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
4. Snap the lanyard to a secure place on the opera BEFORE START UP tor s clothing or life vest not where it might tear away instead of activating the stop switch Verify crankcase oil level before start up Refer to Crankcase Oil Review and follow Break In 10 hours if the en Lo 5 PUSH KEY IN FOR FULL CHOKE gine is new You MUST supply water to the engine before at FG 2 tempting to start it Engine damage can occur quickly Refer to Engine Overheating or Flushing Be sure the engine is in the normal operating posi tion Refer to Tilting 1 3 dr6819 dr5992a 1 Clip 2 Emergency stop key switch 3 Lanyard Engine Starting 21 IMPORTANT The engine will start and run without the clip connected to the key switch However we strongly recommend that the operator use the clip and lanyard anytime the engine is running Refer to Emergency Stop Key Switch Move the tilt lock lever to the LOCK position 1 Tilt lock lever LOCK position Move the remote control handle to NEUTRAL Re fer to Shifting and Speed Control Raise the fast idle lever The higher you raise the fast idle lever the faster the motor will idle in NEU TRAL DRC5987 1 Fast idle lever 2 NEUTRAL WARNING Always shift to NEUTRAL before starting the engine to prevent sudden boat move ment which can cause injury AN Start up Cold Engine Starting a cold engi
5. To avoid engine damage after start up do not exceed 2000 RPM in NEUTRAL Do not exceed 1500 RPM in NEUTRAL for extended peri ods of time Check the water pump indicator A steady stream of water indicates the water pump is working If a steady stream of water from the water pump indica tor is not visible stop the engine Refer to Engine Overheating 1 Water pump indicator ENGINE STOPPING Move control handle to NEUTRAL Turn key switch counterclockwise to OFF Remove the key when the boat will be unattended To avoid difficulty when restarting never stop the engine by running it with the fuel hose disconnected or otherwise running it out of fuel Engine Starting 23 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 If the following direc tions are not suitable for your boat s control see your Dealer before proceeding Shifting With engine running and control handle in NEU TRAL Side Mount and Concealed Side Mount Control Unlock the control handle lift the neutral lock tab by squeezing the hand grip Briskly and decisively move the control handle fore or aft until it engag es the gear detent Sy f senda dr21155 dre4014 1 Side mount NEUTRAL lock tab hand grip 2 Concealed side mount NEUTRAL lock tab hand gri
6. how ever 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
7. Guard grease onanouwrnstogs g o Evinrude Johnson Molylube P N 175356 Starter Bendix Lube Only P N 337016 Evinrude Johnson Engine Tuner Evinrude Johnson Ultra 4 Stroke synthetic blend oil Evinrude Johnson anti corrosion spray or Evinrude Johnson 6 in 1 multi purpose lubricant 46 Maintenance INSTALLATION A WARNING A 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 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 tran som 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 hard ware 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 heigh
8. 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 sys tem 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 igni tion system and catalytic converter Also included may be hoses belts connectors and other emission related 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 John
9. Pot System Throttle Body Assembly Idle Air Control Closed Throttle Position Switch Throttle Linkage xX Intake Manifold X Sensors Air Temperature Sensor Cam Position Sensor Crankshaft Position Sensor XxX Throttle Position Sensor Exhaust Temp Sensor Intake Manifold Pressure Sensor Cylinder Temperature Sensor X Gaskets All Emission Component Gaskets X XD XD x lt x lt x lt Xx Xx x lt x lt x lt X lt XXX lt lt Xx lt lt DD lt lt KK KK OK OK OK OK OX DE KK KK OK X x lt 10 General Information The emission warranty covers damage to other engine components that is caused by the failure of a war ranted 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 out board 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 warr
10. Remove drain fill plug and lubricant level plug from side of gearcase and completely drain gearcase of old lubricant 2 Examine drained lubricant for metal filings milky appearance or black color with burnt odor If old lubricant has any of those charac teristics see your Dealer If drained lubricant is in good condition continue 3 Place tube of lubricant in drain fill hole and fill slowly until lubricant appears at lubricant lev el hole See Engine Specifications for gear case capacity 4 Install lubricant level plug before removing tube from drain fill hole Drain fill plug can then be installed without loss of lubricant 5 Securely tighten both plugs 1 Drain fill plug 2 Lubricant level plug IMPORTANT To avoid insufficient injection of lu bricant check the gear oil level 10 minutes after fill ing If the oil level is low slowly inject the lubricant up to the correct level Maintenance 39 Lubrication Points BREATHER AND FUEL LINE Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom Inspect the breather and fuel line for leaks cracks mended lubricant swelling or other damage If the breather and fuel line are damaged in any way they must be re placed See your Dealer 1 Breather line 1 2 Fuel line AL ars 1 Swivel bracket 2 Clamp screws Fuel line WARNING Leaking fue
11. content does not exceed 10 ethanol by volume or 5 methanol with 5 cosolvents by volume Minimum Octane Inside the U S Outside the U S 87 R M 2 AKI 90 RON Your outboard has been designed to operate using the above fuels however be aware of the follow ing The boat s fuel system may have different require ments 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 perfor mance 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 WARNING A 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 A 18 Fuel and Oil OIL Your 4 stroke engine requires oil in the crankcase Evinrude Johnson Ultra 4 Stroke synthetic blend oil is recommended for this outboard en gine It allows for extended oil change intervals and is best for high load applications Evinrude Johnson Ultra 4 Stroke synthetic blend oil delivers ultra vis cosity stability sludge protection friction reducing proper
12. 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 19 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 proper ly 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
13. of serious damage ANTICORROSION ANODES Your motor is equipped with one or more anodes that protect it from galvanic corrosion Refer to Fea tures for anode location Disintegration of the an ode is normal and indicates it is working Check each anode periodically Replace anodes smaller than 2 3 their original size See your Dealer for re placements Galvanic corrosion destroys underwater metal parts and can occur in fresh or salt water however salt brackish and polluted waters will accelerate corrosion Metal based antifouling paint on the boat or motor and the use of improperly installed shore power in the area of your moored boat will also accelerate corrosion IMPORTANT NEVER paint the anode its fasten ers or its mounting surface Painting will reduce its corrosion protection BONDING WIRES 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 42 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 requi
14. plug PROPELLER A WARNING To avoid accidental starting of engine while changing propellers twist and remove all spark plug leads A IMPORTANT Apply Triple Guard grease to the en tire propeller shaft before installing the propeller At least annually remove the propeller and check for debris Clean the shaft and regrease it before rein stalling 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 Ibs 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 6543 2 1 Stopper Propeller Spacer Washer Propeller nut Cotter pin D Ue O N a Maintenance 41 Repair If your propeller hits a solid object the impact is par tially absorbed by the rubber bushing in the hub to help prevent damage to the engine A strong impact can damage the hub and propeller blades Damage to blades can cause unusual and excessive vibra tion Damage to the hub can cause excessive en gine RPM with little forward movement IMPORTANT Avoid or limit operation using a dam aged propeller Carry a spare propeller Keep your propeller in good condition Use a file to smooth slight damage to blade edges See your Dealer for repair
15. portion provides proof of ownership and date of purchase Outside North America See your Dealer or distributor for details Model and Serial Numbers The model and serial numbers appear on a plate at tached to the stern bracket or swivel bracket Record your outboard s Model Number Serial Number Purchase Date 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 Declaration of Conformity BRP declares that the outboard to which this Oper ator s Manual applies conforms to the essential re quirements outlined in CE Machinery Directive 98 37 EC as amended 4 General Information BRP LIMITED WARRANTY FOR 2006 JOHNSON 4 STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA 1 SCOPE OF THE LIMITED WARRANTY Bombardi
16. ventilated area away from heat and open flame Prevent escape of liquid or vapors which could acci dentally ignite Close the filler cap vent screw if equipped Be sure the discon nected fuel hose does not drip A PRE SEASON SERVICE Remove your outboard from storage and prepare it for a season of reliable service by performing a gen eral check and a few preventive maintenance pro cedures 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 AN WARNING A Failure to carefully reattach the outboard and its control systems with factory speci fied hardware can result in sudden unex pected 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 in stall 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 A Top off fuel tank w
17. ICATIONS BRP LIMITED WARRANTY FOR 2006 JOHNSON 4 STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA nnrsvrsvsnrnonvrnrnnrsvnnennnsnrnvsnnnnssennernrnenneenennsnnsnennrsesnnnnennnnennvsnsnnsner 5 BRP LIMITED WARRANTY FOR 2006 JOHNSON 4 STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA rsrsoravrsvrsrsvrnvsnnennnvrnesnennsnensenvnnesnvsnnnnrsesnennnnnsnvsnssnssesner 8 CALIFORNIA EMISSION CONTROL WARRANTY STATEMEN 9 FEATURES 12 ENGINE SPECIFICATIONS REMOTE CONTROL 15 ENGINE MONITORING 17 FUEL AND OIL vnnnesvsnensvnnennvnnensennnnnnnsnnnnsennvnnensvnnensensennennennnnnnnnnennnnnenvennensennennvnnennnnnnnnsnensene 18 FUEL O SEEE IAE E E E ET E EE 18 OIL 19 ADDITIVES FUEL SYSTEM BREAK IN 10 HOURS ENGINE STARTING BEFORE START UP ENGINE STOPPING SHIFTING AND SPEED CONTRO EMERGENCY STARTING FUEL ECONOMY OPERATION Ea E T T E E TT MOTOR ANGLE ADJUSTMENT TILTING osnnenornornrnornernennrnersennrseen SHALLOW WATER DRIVE MOORING 2eeeeeeeee FLUSHING rssnnornornvnnrnnnsersennrser LOW OIL PRESSURE WARNING OVER REVOLUTION LIMITING SYSTEM ENGINE OVERHEATING csc0e0 TRAILERING IMPACT DAMAGE STORING nrnvrsvsnrsornersvsvnsernesnrsenn CARRYING AND TRANSPORTING SPECIAL OPERATING CONDITIONS MAINTENANCE msrnnersvsnvnsvsvesnr 34 ENGINE EMI
18. ING 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 28 Operation FLUSHING DANGER AN A 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 WARNING Prevent injury from contact with rotating propeller remove the propeller before flushing AN Outboard Running 1 Place the engine in vertical position in a well ventilated area with good drainage 2 Install flushing device and garden hose 3 Cover the water intake hole with 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 1 Flushing device 2 Tape 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 wa ter must flow If it does not shut OFF the en gine and investigate Refer to Engine Overheating N 1 Water pump indicator 7 Leave the outboard in vertical position long enough to completely drain the powerhead LOW OIL PRESS
19. Operator s Guide 9 9 15 HORSEPOWER EL4 4 Stroke 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 mainte nance 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 recommen dation 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 boat ing 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 aroun
20. Operators Guide uses the following signal words identifying important safety messages These safety alert signal words mean ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED DANGER A Indicates an imminently hazardous situa tion which if not avoided WILL result in death or serious injury AN A WARNING A Indicates a potentially hazardous situation which if not avoided CAN result in severe injury or death AN CAUTION A Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate personal injury or property dam age 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 op eration 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 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 reg ulations call U S Coast Guard Boating Safety Hot line 1 800 368 5647 Outside North Ameri
21. SSIONS INFORMATION 34 10 HOUR INSPECTION nnssssrvns0 35 OFF SEASON STORAGE PRE SEASON SERVICE CRANKCASE OIL ADJUSTMENTS 38 LUBRICATION 00000 39 BREATHER AND FUEL LINE 40 SPARK PLUGS 0 41 PROPELLER 20000000 41 ANTICORROSION ANODES 42 BONDING WIRES 42 BATTERY scsseeseeseee TROUBLE CHECK CHART ENGINE MAINTENANCE AND INSPECTION SCHEDULE 45 INSTALLATION merenernvnnvnnvsvnnvnnensersvssensersesnensenn 47 TRANSOM HEIGHT AND SHAFT LENGTH 47 INSTALLING THE ENGINE cccssscscssssscssssesssneesssnsesssnsessssseesssneesssnsesssnsessssneessaseesssneesssnecessnuecsssnecessasenssanecesanecsesn 48 O 2005 BRP US Inc All rights reserved TM Trademarks and registered trademarks of Bombardier Recreational Products Inc or its affiliates GENERAL INFORMATION SAFETY THE RIGHT PLACE TO GET STARTED This Operator s Guide contains essential informa tion to help prevent personal injury and damage to equipment It will acquaint the operator and pas sengers with the Evinrude Johnson outboard and its controls operation maintenance and boating safety measures Make sure all operators read un derstand and follow the contents This Guide should be kept in a waterproof bag with the product at all times during operation If the product owner ship is transferred this Guide should be forwarded to the subsequent owners This
22. URE WARNING Should crankcase oil pressure drop to a danger ously low level during engine operation the low oil pressure light will come on 1 Low oil pressure light 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 en gine If tilted place the engine in vertical position Operation 29 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 oper ate 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 IMPORTANT Do not rely on the low oil pressure light to indi
23. aner 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 stan dards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke 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 stan dards Engines meeting these standards have 20 lower emissions than One Star Low Emission en gines Three Stars Ultra Low Emission The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Out board 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
24. anty 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 ex ists 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 Waukeg an IL 60085 1 847 689 7090 or visit www johnson com General Information 11 FEATURES Item Description Item Description 1 Motor Cover 7 Lubricant Drain Fill Plug 2 Starter Handle 8 Water Intake 3 Clamp Screw 9 Anti Corrosion Anodes
25. bles 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 ca ble even briefly the charging system will be dam A AN 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 43 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 e 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 Sec tion 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 wi
26. ca please contact your Dealer or distributor for details about boating safety SAFETY MEASURES General A To fully appreciate the pleasures enjoyment and excitement of boating there are some ba sic rules that should be observed and fol lowed 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 A Become completely familiar with the control and operation of your boat and motor before embarking on your first trip or taking on a pas senger s If you have not had the opportunity to do so with your Dealer practice driving in a suitable area and feel the response of each control Be familiar with all controls before ap plying the throttle above idle speed As the operator you are in control and responsible for safe operation SAFETY MEASURES Operation A Be sure at least one of your passengers knows how to handle your boat in case of an emergency A All passengers should know the location of emergency equipment and how to use it A All safety equipment and personal flotation devices must be in good condition and suit able for your type of boat Always comply with the regulations that apply to your boat A Contact with rotating propeller is likely to re sult in serious injury or death Do not allow anyone near a prop
27. cate the need to add oil Be sure to peri odically check the engine oil level If the oil level is low severe engine damage can result OVER REVOLUTION LIMITING SYSTEM This system is activated when engine speed ex ceeds maximum recommended speed for more than 10 seconds If this system activates engine speed will automat ically 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 Sys tem will not be activated at recommended maxi mum 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 en gine is running the engine s water pump indicator must discharge a steady stream of water Check the indicator often especially when operating in weeds muddy and debris laden water at extreme trim angles or in shallow water drive if equipped 1 Water pump indicator If the stream from the water pump indicator be comes intermittent or stops reduce
28. 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 fac tory standards For this reason the factory proce dure for servicing the product must be strictly followed and whenever practicable returned to the original intent of the design The responsibilities list ed above are general and in no way a complete list ing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products For more detailed information on this sub ject 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 EPA INTERNET WEB SITE www epa gov A WARNING A Only perform service procedures which are detailed in this Operator s Guide Attempt ing 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 34 Maintenance 10 HOUR INSPECTION After 10 hours of operation your new engine will be broken in and
29. d you Having fun is what it s all about and with your cooperation the pertinent information in this Guide can en sure a safe and enjoyable experience Enjoy the great outdoors on the water A WARNING A Be careful Human error is caused by many factors carelessness fatigue overload preoccu pation unfamiliarity of operator with the product drugs and alcohol to name a few Damage to your boat and outboard can be fixed in a short period of time but injury or death has a lasting effect For your safety and the safety of others read this Guide from cover to cover and follow all safety warnings and recommendations Do not disregard any of the safety precautions and instructions Anyone operating your boat should first read and understand this Guide before they operate your boat and motor The following trademarks are the property of Bombardier Recreational Products 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 94J12 BBD Contents GENERAL INFORMATION i ennnevrnvnennennvnnenvennennenvnnnnsvnnvnnennennennennnnnvsnnnnnnvnnnnnnnnennennennenvennennnnnn SAFETY THE RIGHT PLACE TO GET STARTED PRODUCT REFERENCES ILLUSTRATIONS AND SPECIF
30. ddress 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 understand and agree to be bound with I am also satisfied with the predelivery set up and inspection of my Evinrude Johnson Outboard have also received a copy of the Operator s Guide Signature Date Readiness Test and a Final Word to the Owner Operator The Operator s Readiness Test 1 2 3 4 Did you read this Guide from front cover to rear cover Are you ready to take responsibility for the safe operation of your boat and motor Do you understand all the safety precautions and instructions contained in this Guide Do you understand that this Guide contains essential information to help prevent personal injury and damage to equipment Are you ready to follow the recommendations in this Guide and take a boating safety course before you operate your boat and motor Do you know who to ask if you have any questions about your boat and motor Do you know your local marine traffic laws Do you understand that human error can be caused by carelessness fatigue overload preoccupa tion unfamiliarity of operator with the product drugs and alcohol just to name a few WARNING It is impossible for this Guide to cover every hazardous situation you may encounter
31. e last hours of operation to ensure proper stabilization following instructions on the container for mixture Be sure to run the engine long enough for the treated fuel to reach the en gine A WARNING A Prevent injury from moving engine compo nents Before starting the engine Shift it to NEUTRAL Keep hands clothes and hair clear of pow erhead Remove the propeller if you use a flushing device 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 min utes to warm the crankcase oil Stop the engine and drain the crankcase while the engine is warm Refill it with Evinrude Johnson Ul tra 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 af ter 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
32. e your boat and outboard prudently and have fun Do not forget that all persons must assist other boaters in case of emer gency A Prevent injury from contact with rotating pro peller remove propeller before flushing or before performing any maintenance General Information 3 PRODUCT REFERENCES ILLUSTRATIONS AND SPECIFICATIONS A WARNING IN When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Using substan dard parts could result in injury or product malfunction Bombardier Recreational Products BRP reserves the right to make changes at any time without no tice to features specifications and model availabil ity The right is also reserved to change any specification or part at any time without incurring any obligation to update older models The informa tion in the Guide is based on the latest specifica tions 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 ar eas Owner s Identification North America At the time of purchase your Dealer will complete your outboard registration forms Your
33. eller even when the en gine 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 2 General Information Whenever running the engine assure there is proper ventilation to avoid carbon monox ide 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 oth er 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 concentra tions CO can be fatal within minutes Lower concentrations are just as lethal over long pe riods of time A 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 A Be familiar with the waters you are operating in The gearcase of this outboard extends be low the water surface and could potentially come in contact with underwater obstruc tions Contact with underwater obstructions may result in loss of control and perso
34. er Recreational Products Inc BRP warrants its 2006 Johnson 4 stroke outboard engines sold by authorized Johnson dealers in the fifty United States and Canada Product from defects in ma terial 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 hun dred 200 hours of engine use whichever occurs first The Product is used commercially when it is used in connection with any work or employment that generates income during any part of the warranty period The Product is also used commercially when at any point during the warranty period it is installed ona boat that has commercial tags or is licensed for commercial use The repair or replacement of parts or the performance of service to Product under this warranty does not extend the life of this limited warranty beyond its original expiration date All Evinrude Johnson Genuine Parts and accessories installed by an authorized dealer at the time of sale including but not limited to pro pellers bear the
35. er 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 e 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 e 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 e Product is or has been used for racing at any point even by a prior owner 6 General Information 7 LIMITATIONS OF LIABILITY ALL WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA TION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY 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 reins
36. erate the motor only at very low speeds 26 Operation RELEASE Position UP Use the RELEASE position in FORWARD when you are unsure of depth or concealed objects Plac ing the tilt lock lever in the RELEASE position al lows the motor to tilt up if you strike an underwater object reducing the chance of damage to the mo tor Refer to Shallow Water Drive for details on shallow water operation 1 Tilt lock lever RELEASE position A CAUTION A When you operate the motor with the tilt lock lever in the RELEASE position forces such as propeller thrust during operation in REVERSE rapid deceleration and striking an underwater object can cause the motor to lift out of the water resulting in personal injury To avoid such injury use the RELEASE position only for shallow water operation and operate the motor with cau tion and only at very low speeds Tilt Support The tilt support is used to hold the motor in the fully tilted up position IMPORTANT DO NOT use the tilt support while trailering Refer to Trailering WARNING DO NOT place your hands near the mount ing bracket or under the motor when tilting or they could be crushed if the motor slips from your grasp AN Move the tilt lock lever to the RELEASE position 1 Tilt lock lever RELEASE position Grasp tilt grip on engine cover and tilt motor to the full tilt position Tilt support will auto
37. he 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 gear case or remained in the cooling system or other components can freeze causing serious engine damage Submerged Engine If your engine has been under water have it ser viced 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 fu el 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 e Shift your engine to NEUTRAL e Tilt its gearcase out of the water and e Off load all persons into another boat Keep towing speed slower than planing speed Operation 33 MAINTENANCE Maintenance replacement or repair of the emission control devices and systems may be performed by any marine SI spark ignition en gine repair establishments or individual ENGINE EMISSIONS INFORMATION Manufacturer s Responsibility Beginning with 1999 model year engines manufac turers of marine engines must determine the ex haust emission levels for each engine horsepower family and certify these engines with the Uni
38. heel pul ley 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 1 NEUTRAL 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 en gine cover while engine is running If equipped at tach emergency stop switch s lanyard to a secure place on your clothing Proceed to nearest harbor for service FUEL ECONOMY The economy throttle range can save fuel depend ing on boat load and hull design When boat reach es top speed throttle back from FULL SPEED to the economy throttle range You will save fuel with out a noticeable loss of speed DR6472 DR6506 a Concealed side mount control 2 Binnacle mount control Engine Starting 25 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 A WARNING A 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 e
39. ith 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 VAN Failure to check for fuel leakage could allow a leak to go undetected resulting in fire or explosion AN 36 Maintenance CRANKCASE 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 4 Stroke synthetic blend oil Refer to 10 Hour In spection Checking Check the oil level when the engine is cold to en sure an accurate reading 1 Place the engine in a vertical position and re move the upper engine cover 2 Remove dipstick wipe it clean and install it 1 Oil level dipstick 3 Remove the dipstick again and locate the li
40. 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 En gine Maintenance and Inspection Schedule 10 Hour Inspection for a partial list Follow consistent preventive maintenance by hav ing 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 corro sion of internal engine parts when they are not pro tected 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 rec ommend 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 con ditioner during th
41. l 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 1 Steering bracket 40 Maintenance SPARK PLUGS 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 cau tion to avoid injury from shock or injury resulting from your reaction to shock Do not handle primary or secondary ignition components while the engine is cranking or running Inspect spark plugs periodically Replace if elec trodes 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 Speci fications IMPORTANT Avoid engine damage by installing spark plugs into COOL cylinder head and not over tightening 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 be tween the spring terminal and the spark plug 02333 1 Ribbed portion of the spark
42. ler for a copy of Introduction to High Performance Boating P N 335763 SAFETY MEASURES Installation and Maintenance Outboard Installation A 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 A Do not overpower your boat by using an en gine 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 Maintenance Z When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Using substan dard parts could result in injury or product malfunction A Only perform service procedures which are detailed in this Operator s Guide Attempting to perform maintenance or repair on your out board 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 cer tain service or repair procedures A Maintain your boat and engine in top condi tion at all times Adhere to the Engine Main tenance and Inspection Schedule Z Operat
43. ll not idle properly Motor angle excessive Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel system contaminated with water or dirt Engine loses power Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel filter obstructed Fuel system contaminated with water or dirt Water intakes obstructed and cooling system not operating cor rectly 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 44 Maintenance ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products Periodic maintenance contributes to the product s life span The following maintenance chart provides guidelines for engine maintenance and in spection scheduled to be performed by you and or by an authorized Dealer The schedule should be ad justed according to operating conditions and use The recommended lubricants have been formulated to protect bearings gears and engine components They must be used to avoid damage caused by impr
44. ll 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 20 Fuel and Oil ENGINE STARTING Connect the fuel hose to the fuel connector A DANGER A 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 A WARNING A 1 Fuel hose to fuel connector The engine cover is a machinery guard DO NOT operate your outboard with the cover If equipped open vent screw on fuel tank s filler off unless you are performing maintenance cap and then be careful to keep hands hair and Jt clothing clear of all moving parts Contact Squeeze fuel primer bulb outlet end up until firm with moving parts could cause injury A WARNING IN 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 C NN 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 dre3915 Connect the clip to the emergency stop key switch
45. matically en gage 1 Tilt support WARNING Disconnect the fuel line whenever you leave the motor tilted up for a long period of time or fuel may leak out Tilt Down Grasp tilt grip on engine cover and raise motor slightly The tilt support will disengage Slowly lower motor to its normal operating position Operation 27 SHALLOW WATER DRIVE The motors depth in shallow water drive is con trolled by the position of the motor angle adjusting rod Relocate the motor angle adjusting rod if nec essary Refer to Motor Angle Adjustment Slow the engine and shift to NEUTRAL before en gaging or disengaging shallow water drive VAN WARNING Drive When using the Shallow Water Bracket the Tilt Lock feature will not work 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 Move the tilt lock lever to the RELEASE position 1 Tilt lock lever RELEASE position Tilt the motor up until you hear a click sound and it is held in the fully tilted up position Slowly lower motor until shallow water drive brack et rests against angle adjusting rod IMPORTANT Check often that water intakes are completely submerged and the water pump indica tor is discharging a steady stream of water MOOR
46. 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 in jury to boat occupants from the engine or its parts entering the boat Occupants can also be ejected or injured by falling against portions of the boat as a result of rapid deceleration following impacts When boating in unfamiliar shallow or debris laden wa ters seek information on safe boating areas and navigation hazards from a reliable local source Re duce your speed and keep a sharp lookout dr4411 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 dr4412 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 exam ine 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 com ponents IN WARNING A Failure to inspect for damage could result in sudden unexpected component failure loss of boat control and per
47. n Ultra HPF gearcase lubricant Capacity 5 7 fl oz 107 ml Propeller 9 1 4 x Qin Fuel Tank Capacity 3 U S gallons 11 4 liters Weight EL 104 7 Ibs 47 5 kg Transom Height EL 19 1 2 to 20 in 495 to 508 mm Sound at Driver s Ear Lpa ICOMIA 39 94 9 9 79 6 dB A 1 Rated following the standards of ICOMIA 28 83 ISO 3046 and NUMA 2 Emission Control Information 3 Not supplied in all marketing areas 14 General Information REMOTE CONTROL WARNING If you choose a non Evinrude Johnson remote control be sure it has a start in gear preven tion feature This feature can prevent injuries resulting from unexpected boat movement when the engine starts IMPORTANT When selecting the remote control system for your boat specify Evinrude Johnson com ponents Evinrude Johnson offers remote controls cables and wiring kits designed specifically for your Evinrude Johnson outboards Evinrude Johnson controls deliver the cable stroke your outboard needs for positive shift and throttle control and they incorporate such safety and convenience features as e Start in gear prevention e Plug in compatibility with Evinrude Johnson modular wiring system Evinrude Johnson Redesigned side mount control Handle shift and throttle Trim tilt switch where equipped Neutral lock tab Fast idle lever Throttle friction control Emergency stop clip and lan
48. n infor mation Installation 47 INSTALLING THE ENGINE Center the engine on the boat s transom or mount ing 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 1 Clamp screws 2 Accessory transom plate Bolt your engine to the boat s transom using 8 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 tran som Be sure to drill holes at right angles to the tran som 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 wash ers that contact the transom Avoid RTV silicone and polyurethane sealants as they can be dis solved by gasoline Secure the engine with the mounting hardware po sitioned 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 When replacing bolts screws and other fasteners use Evinrude Johnson Genuine Parts or parts of equivalent strength and material AN 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 ca
49. nal in jury A Avoid standing up or shifting weight suddenly in light weight boats A Keep your passengers seated in seats The boat s bow gunwale transom and seat backs are not intended for use as seats A 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 nonswim mers at all times A 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 over board A Know the marine traffic laws and obey them A 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 des tination 1 3 back and 1 3 reserve fuel supply Do not carry spare fuel or flammable liquids in any storage or engine compartments A Do not operate your boat if you are under the influence of drugs or alcohol A High performance boats have a high power to 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 A For more information see your Evinrude Johnson Dea
50. ne of oil If the line of oil is not between the ADD and the FULL marks you must add or re move oil as indicated 1 Full 2 Add 4 Securely install the dipstick and wipe up any spilled oil IMPORTANT Operating the engine with too much or too little oil in the crankcase will damage it Changing the Oil 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 4 Stroke synthetic blend oil Refer to 10 Hour In spection 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 com pletely 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 dur ing storage TAN A Used motor oil may be harmful Avoid pro longed and repeated skin contact Wash affected skin with soap and water CAUTION 1 Place the engine in a vertical position and re move the upper engine cover 2 Unscrew and remove the oil fill cap 1 Oil fill cap 2 Dipstick Maintenance 37 3 Hold a suitable container under the oil drain screw Remove the screw and drain the re servior Befo
51. ne normally requires use of the engine primer To activate the primer steadily PUSH HOLD the key switch IN while cranking or running the engine With the fast idle lever up activate the primer while turning the key switch to the START position Crank the engine no longer that 10 seconds Release the key upon start up and quickly adjust the fast idle le ver if the engine overspeeds dre5988 1 PUSH to activate primer 2 START IMPORTANT The starter motor can be damaged if operated continuously for more than 10 seconds Upon start up release the key If the engine did not start release the key momen tarily then try again Each time the key switch is turned from OFF to ON the warning system will self test Refer to Engine Monitoring If the warning system fails to self test during start up see your Dealer 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 A If your outboard does not react normally to this starting procedure or it fails to start refer to Trouble Check Chart 22 Engine Starting After Engine Starts DO NOT turn the key switch to START while the en gine is running Damage to the starter system could result Allow the engine to idle in NEUTRAL for about 5 minutes to warm up before shifting IMPORTANT
52. normal starting procedure Reinstall a clip as soon as possible PUSH KEY IN FOR FULL CHOKE dr6819 dr5992a 1 Clip 2 Emergency stop key switch 3 Lanyard A WARNING A Avoid knocking or pulling the clip off the stop switch during normal boating Avoid bumping the key if operating without the clip on the switch The resulting unexpected loss of forward motion can throw occupants forward causing injury Your emergency stop switch can be effec tive only when in good working condition At each outing inspect clip and lanyard for cuts breaks or wear Replace worn or dam aged 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 16 General Information ENGINE MONITORING IMPORTANT Your outboard must be equipped with the System Check or equivalent engine monitor Operating your outboard without the Sys tem Check or equivalent engine monitor will void your warranty for failures related to the functions monitored on your engine When you turn the key switch ON the System Check engine monitor horn performs a self test by sounding a 1 2 second beep The gauge self tests by turning the warning lights on then off in se quence During engine start up pause with the key switch in the ON positi
53. nspect and verify operation 2 D D Engine to transom mounting hardware re torque D D Clamp screws tighten O Electrical and ignition wires and connections inspect D D Gearcase lubricant replace 5 D D Propeller shaft splines inspect and lubricate 6 D Powerhead synchronization and linkage inspect 2 6 D D Starter pinion shaft inspect and lubricate 3 8 D Spark plugs replace D Decarbonize 9 D Maintenance 45 Engine Maintenance and Inspection Schedule Frequency g g 5 3 3 gt og I gt Iz o 5 oF os oO 1 oc o 5 oc 5 5 90 2 Ne F 128 PE as Engine Care g To go gc ga Description Product w 2s m5 ri o Timing belt Replace every 4 years Valve tappet clearance inspect 2 D D Driveshaft splines inspect and lubricate 7 D Water pump inspect and replace D Carburetor inspect D Breather line replace D Crankcase oil level check O D Crankcase oil replace 4 10 D D Fuel filter replace D Oil filter replace D D Ignition timing check D Operator s Guide onboard O Operator s Guide review 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 Dealer Performed Service Operator Performed Service Ultra HPF gearcase lubricant Triple
54. on 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 pro peller area and water intakes before operating at higher speed Boat Bottom and Engine External Finish The condition of your boat s bottom affects perfor mance 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 wa ter and wipe it dry Apply Evinrude Johnson anti corrosion 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 High Altitude 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 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 t
55. on to observe the horn and gauge perform the self test If the self test does not happen as stated see your Dealer The System Check engine monitor alerts the oper ator with a 10 second beep of the horn and a warn ing light on the gauge when certain engine problems occur The appropriate warning light will stay on until the key switch is turned OFF NO J OIL WATER TEMP CHECK U ENGINE LOW pa OIL dr5206 dr5364 System Check Gauge System Check Gauge with Tachometer WATER TEMP or HOT The engine is overheating Serious engine damage can occur quickly If the engine is overheating it will also limit engine speed to 2000 RPM This additional protection fea ture is referred to as S L O W If the engine was running faster than 2000 RPM when the S L O W system activated it will shake noticeably IMPORTANT Refer immediately to Engine Over heating NO OIL or LOW OIL If during operation your engine begins vibrating noticeably and will not exceed 2000 RPM fast idle the low oil pressure warning might have been acti vated The engine s warning system automatically limits its RPM when crankcase oil pressure falls be low what the engine requires Oil pressure can fall due to operating conditions such as rough seas or it can fall in response to in sufficient supply of oil Once the engine s warning system has been activated you must take appropri ate action to restore ade
56. oper 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 Frequency 2 LETT ez lgs 5 159158 72 129 zE BE zs ul Engine Care ie selec jee lee Description Product Ww j s S WU 6 Swivel bracket inspect and lubricate 1 6 Every 60 days Every 30 in Saltwater Throttle linkage inspect and lubricate 0 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 4 Every 60 days Every 30 in Saltwater components Battery connections and condition verify 6 O D Anticorrosion anodes and bonding wires verify D operation 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 0 D Emergency stop circuit and lanyard verify function O D Flush cooling system O Fuel components inspect and repair leaks 2 D D Fastener inspection tighten loosened components D D Engine upper and lower motor covers clean and wax O Gearcase lubricant inspect fill level and condition of 5 D lube Thermostat i
57. p Binnacle Mount Control Briskly and decisively move the control handle fore or aft until it engages the gear detent DR5986 IMPORTANT When shifting from FORWARD to REVERSE or from REVERSE to FORWARD pause at NEUTRAL until the engine is at idle speed and the boat has slowed Speed Control After gear engagement move the control handle slowly in the same direction to increase speed Fast Idle in NEUTRAL Concealed Side Mount and Binnacle Mount Controls IMPORTANT Avoid excessive engine RPM in NEUTRAL adjust the throttle so the engine does not overspeed With the control handle in NEUTRAL push the fast idle button while using the other hand to move the control handle forward past the forward gear de tent and into the throttle range If equipped with a neutral lock tab squeeze it to begin handle travel DR5986 21154 1 Fast idle button When ready to shift move the control handle back to NEUTRAL Engine speed will reduce and the shift function will automatically engage for move ment into FORWARD or REVERSE EMERGENCY STARTING A WARNING A When using Emergency Starting proce dures the start in neutral only feature is inoperative Make sure shift lever is in NEU TRAL 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 compo nents keep hands clothes and hair clear of powe
58. ptly contacts BRP or Dealer and gives the name and address of the new owner 9 CONSUMER ASSISTANCE e 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 e 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 2005 General Information 7 BRP LIMITED WARRANTY FOR 2006 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 Resourc es Board The label has one two three or four stars A hangtag provided with your outboard describes the meaning of the star rating system The Star Label means Cleaner Marine Engines LOW Gul Emissio The Symbol for Cle
59. quate oil pressure and re set 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 Engine Monitoring 17 FUEL AND OIL FUEL A WARNING A 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 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 ter tiary 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
60. rd 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 gt 2 Change of address Change of ownership Model number Serial Number Old address Previous owner Last name First name M Address City State Zip code Country Phone number Signature Date New address New owner Last name First name M Address City State Zip code Country Phone number Signature Date 000063 Bombardier Recreational Products EVINRUDE JOHNSON DEALER SUPPORT SERVICES 250 SEAHORSE DRIVE WAUKEGAN IL 60085 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 A
61. re you reinstall the screw re place the gasket with a new one Reinstall the screw and tighten it securely 1 Oil drain screw 2 Pour the recommended oil into the oil fill until it reaches the upper mark on the dipstick Re fer to Engine Specifications for crankcase capacity 3 Replace the oil fill cap and clean any spilled oil off the engine and your skin 4 Reinstall the upper cover 5 Supply water to the cooling system and run the engine at idle to check for leaks especial ly around the oil filter drain screw and oil fill cap Correct any problems 6 Stop the engine and recheck crankcase oil level using the dipstick Add oil as indicated ol 4 oll lt 2 1 Full 2 Add Dispose of used oil in a reasonable manner follow ing all local regulations ADJUSTMENTS Throttle Friction Adjust throttle friction on your remote control to maintain its position and prevent unwanted throttle creep under normal operating conditions To adjust start engine and move control handle into FORWARD throttle range While underway turn adjustment knob clockwise to increase friction The friction adjustment is effective only in the FORWARD throttle range dre5993 1 Throttle friction control See your Dealer for throttle friction adjustments on your specific remote control Steering Friction The steering friction was set on your new motor be fore it left the factory
62. rements Ask your Dealer about your outboard s require ments before installing longer battery cables a bat tery switch or a battery insulator Installation Read and understand the safety information sup plied with your battery BEFORE you begin installa tion 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 motors BLACK battery cable to the battery s negative post in the same manner WARNING IN Keep the battery connections clean tight and insulated to prevent their shorting or arcing and causing an explosion If the bat tery mounting system does not cover the connections install covers Check often to see that connections stay clean and tight A dr5103 dr5104 1 Large surface star washer 2 Cover Tighten all connections securely and coat the in stallation 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 re move both battery ca
63. rhead Prevent electric shock by keeping clear of the ignition coils and spark plug leads when the motor is being started or is running Shock can cause serious personal injury under certain conditions DO NOT turn flywheel by hand Use starter cord only 24 Engine Starting If the electric starter fails or the battery s voltage is too low to power the starter use the cord from the tool kit and these instructions to start your engine manually IMPORTANT The battery must have enough re serve voltage to activate the electric pump or the engine will not start using the emergency starting procedures Do your best to determine battery sta tus by listening for the electric fuel pump audible cy cle before continuing the emergency starting procedures The electric fuel pump cycles each time the key switch is turned from OFF to ON Place key switch in OFF position with the motor in normal operating position Refer to Tilting Move the control handle to NEUTRAL then remove engine cover Loosen the lock nut Remove the cable from the bracket Separate end of cable from the cam 1 Locknut 2 Cam Remove four screws securing the manual starter 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 but ton Place knot of starter cord in notch on flyw
64. son 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 regis tered 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 Carbureted SPFI Thermostat 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 Air Induction System Timing Chain Belt and Tensioner Camshaft and Followers Intake Valves Electronic Dash
65. sonal injury Unrepaired damage could reduce your boat and engine s ability to resist future impacts Operation 31 STORING If you must tilt the motor to remove it from the water lower it and allow the cooling system to drain com pletely as soon as you clear the launch area Between uses store your motor in a vertical posi tion For recommendations on extended periods of stor age refer to Off Season Storage 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 Remove the engine cover Remove the snap pin washer pin and fastener from the engine cover latch Also remove the screw below the latch Finally remove the engine cover grommet v3 6 C 2 NN 4 1 i 1 Snap pin 2 Washer 3 Pin 4 Fastener 5 Screw 6 Grommet Remove the three side engine cover bolts 1 Bolts Remove the screw and the starboard engine side cover 1 Screw Loosen the carburetor drain screw and drain the gasoline into a suitable container After draining re tighten the drain screw A WARNING Use a proper safe container to store any gasoline drained from the outboard motor 1 Carburetor drain screw After remo
66. speed to idle and Shift to NEUTRAL SHUT OFF the engine Tilt the motor up Clean the intake screen 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 screen and indicator does not re store the water pump indicator s steady discharge SHUT OFF the engine and do not attempt to oper ate it See your Dealer IF cleaning the screen and indicator does restore the water pump indicator s steady discharge con tinue to idle the engine until it cools IMPORTANT You must restore cooling to the en gine to avoid serious engine damage After any overheat have your Dealer Torque the cylinder head screws Inspect the water pump for excessive wear or dam age Inspect the thermostats Inspect the engine for leaks Check engine oil level 30 Operation TRAILERING Trailer your boat with the motor in a vertical posi tion 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 IMPORTANT Whenever using an accessory traile ring bracket the motor must be restrained Bounc ing during transport will damage the motor and boat s transom IMPACT DAMAGE Your engine has a shock absorption system de signed to help withstand damage from impact with underwater objects at low to
67. 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 reg istration 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 warran ty 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 Produc
68. surance 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 e 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 propel ler bushings and spark plugs e 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 e 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 e Damage caused by abuse misuse abnormal use neglect racing improper operation or operation of the Product in a mann
69. t including any defective part therein to Dealer promptly after the appearance of the defect and in any event within the warranty period and must provide Dealer with reasonable op portunity to repair the defect The expenses of transporting Product to and from Dealer for warranty ser vice are to be borne by the owner If the Product has not previously been registered the owner may also be required to present proof of pur chase to Dealer for warranty repairs Owner is required to sign the repair work order prior to the start of the repair in order to validate the warranty repair All parts replaced under this warranty become the property of 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 in
70. t 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 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 The resulting position of the anti ventilation plate must be 0 to 1 in 0 to 25 mm below the boat s bot tom IMPORTANT If the anti ventilation plate falls out side the 0 to 1 in 0 to 25 mm range the installa tion 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 slip page often occurs resulting in poor boat perfor mance 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 installatio
71. tallation 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 prof its or loss of enjoyment or use of Product SOME STATES PROVINCES OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS LIM ITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR OTHER EXCLUSIONS IDENTI FIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE OR PROVINCE TO PROVINCE No distributor Dealer or any other person is authorized to make any affirmation representation or war ranty regarding Product other than those contained in this limited warranty and if made shall not be en forceable against 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 prom
72. ted States of America Environmental Protection Agen cy EPA An emissions control information label showing emission levels and engine specifications must be placed on each engine at the time of man ufacture 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 cer tification 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 speci fications Exceptions include manufacturers prescribed changes such as altitude adjustments Owner Responsibility 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 lev els to exceed their predetermined factory specifica tions Tampering with the carburetor to change horse power or modify emission levels beyond factory settings or specifications will void the product war ranty EPA Emission Regulations All new 2002 and more recent Johnson outboards manufactured by BRP are
73. ties 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 nor mal operating conditions For your engine s oil ca pacity refer to Engine Specifications IMPORTANT Failure to follow this recommenda tion could void the engine warranty if a lubrication related 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 A WARNING A If your motor is equipped with a quick dis connect 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
74. up of your new en gine Read Engine Starting Engine Stopping and Speed Control Check the crankcase oil level Refer to Crank case Oil Perform prelaunch checks of all equipment Check the gearcase lubricant level Refer to Lu brication Launch the boat and start the engine according to the procedures in Engine Starting e Verify water pump operation often Look for a steady stream of water from the water pump indi cator If the stream of water stops shut off the en gine to prevent damage Find and correct the cause or see your Dealer before you continue Verify shift function by shifting into gear and ob serving that the boat moves and that the move ment is in the same direction as the shifter Change the RPM often Avoid holding a throttle setting longer than 15 minutes e 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 Oper ate 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 set ting Third hour of operation Run the engine in gear at various speeds up to 4000 RPM or 3 4 throt tle only Balance of first 10 hours of operation Run the engine in gear at various engine speeds includ ing fu
75. ven when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water MOTOR ANGLE ADJUSTMENT The motor should be perpendicular to the water when the boat is underway at full speed This ad justment 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 Move angle adjusting rod as shown TILTING IMPORTANT Use the tilt grip to tilt your motor Do not use the tiller handle to raise or lower the motor Tilt Lock Lever The tilt lock lever has two positions The down LOCK position and the up RELEASE position 1 Tilt lock lever LOCK position LOCK Position DOWN Use the LOCK position when operating in RE VERSE and in normal deep water operation where there is no likelihood of striking underwater objects Placing the tilt lock lever in the LOCK position pre vents the motor from lifting out of the water due to forces such as propeller thrust during operation in REVERSE or rapid deceleration A CAUTION If you strike an underwater object with tilt lock lever in the LOCK position severe damage may result even though the force may be sufficient to release the tilt lock When operating the motor in an area where you may encounter underwater objects move the tilt lock lever to the RELEASE position and op
76. ving 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 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 sur face on its port side Protect the engine cover from damage 32 Operation IMPORTANT Do not let the gearcase of the out board sit higher than the powerhead during trans porting or storing Water may drain into the powerhead causing damage to the engine SPECIAL OPERATING CONDITIONS Salt Water Flush the engine internally after use in salt pollut ed or brackish water to help prevent mineral de posits 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 an odic protection for the boat and outboard may be re quired 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 out board to overheat Weeds on the propeller create vibrati
77. yard Danso dr21155 Evinrude Johnson Concealed side mount control Handle shift and throttle Trim tilt switch where equipped Neutral lock tab Fast idle button Throttle friction control akon Evinrude Johnson Binnacle mount control ARON Handle shift and throttle Trim tilt switch where equipped Fast idle button Throttle friction control Emergency stop clip and lanyard Evinrude Johnson Side mount control Oaran Handle shift and throttle Trim tilt switch where equipped Neutral lock tab Fast idle lever Emergency stop clip and lanyard Throttle friction control General Information 15 Emergency Stop Key Switch A combination emergency stop switch and key switch is a feature of Evinrude Johnson prewired remote controls and all Evinrude Johnson control wiring kits Use of the emergency stop feature is highly recommended on all boats Connect the clip to the emergency stop key switch Snap the lanyard to a secure place on the opera tor s clothing or life vest not where it might tear away instead of activating the stop switch Discon necting 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 and retie the lanyard In an emergency situation the engine can be started without the clip in place Follow the

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