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1. DANGER Contact with a rotating propeller is likely to result in serious injury or death Assure the engine and prop area is clear of people and objects before starting engine or operating boat Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water MOTOR ANGLE ADJUSTMENT Motor should be perpendicular to the water when the boat is underway at full speed This adjustment can only be determined by water testing the boat Set angle adjustment for your normal load Place motor in full tilt position Refer to Tilting and Tilt Support Move angle adjusting rod 24 Operation dr4465 dr3279 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 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 DO NOT use the motor s tilt sup port or the shallow water drive bracket as a traile ring bracket TILTING AND TILT SUPPORT WARNING Your motor has impact protection and reverse lock only when the tilt run lever is in RUN position If operated with the tilt run lever left in TILT positio
2. ADJUSTMENTS LUBRICATION FUEL PUMP FILTER SPARK PLUGS PROPELLER ANTICORROSION ANODES leae en cierre TROUBLE CHECK CHART eene ENGINE MAINTENANCE AND INSPECTION SCHEDULE INSTALLATION cr 2003 Bombardier Motor Corporation of America All rights reserved Trademarks and registered trademarks of Bombardier Motor Corporation of America or its affiliates 1 GENERAL INFORMATION SAFETY THE RIGHT PLACE TO GET STARTED This Operators 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 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 Indicates an imminently hazardous situa tion which if not avoided WILL result in death or serious injury A WARNING Indicates a potentially hazardous situati
3. Electric Start While seated press start button to START motor 1 START button 2 NEUTRAL Release start button as soon as engine starts If en gine does not start release button momentarily and then try again Engine Starting 19 IMPORTANT Starter motor can be damaged if erated continuously for more than 10 seconds DO NOT press start button to START position when en gine is running Starter and flywheel will be dam aged All Models Push primer in to RUN no color line showing when motor is sufficiently warmed up IMPORTANT If your outboard does not react nor mally to this starting procedure or fails to start refer to Trouble Check Chart After Engine Starts Check the water pump indicator A steady stream of water indicates the water pump is working If a steady stream of water from the water pump indica tor is not visible stop the engine Refer to Engine Overheating Grid IMPORTANT To avoid engine damage after start up do not exceed one quarter throttle less than 2000 RPM in NEUTRAL for extended periods of time Start up Warm Engine Follow Cold Engine procedure except warm en gines do not normally require priming If your en gine fails to start then use the primer 20 Engine Starting ENGINE STOPPING Twist the throttle grip to SHIFT position or slower Move shift lever to NEUTRAL Press the STOP button until the engine stops run ning If equipped close the
4. Operator s Guide 25 30 HORSEPOWER RU BOMBARDIER a 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
5. 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 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 cables from the battery BLACK cable first Keep metal objects from contacting either battery post IMPORTANT Service electrical components only while the outboard is NOT running Be careful when identifying positive and negative battery cables and posts If you touch the wrong post with a battery ca ble even briefly the charging system will be dam aged WARNING Battery electrolyte is acidic handle with care If electrolyte contacts an
6. 254 a Wee SE drc24502a 000153 Item Description Item Description 19 Mounting Hardware 28 Trim Tab 20 Fuel Tank 29 Anti ventilation plate 21 Idle Speed Adjusting Knob 30 Anticorrosion Anode 22 Steering Handle and Twist Grip Throttle 31 Engine Cover Latch 23 Fuel Connector 32 Spark Plugs 24 Model and Serial Number Plate 33 Starter Cable Locking Tabs 25 Water Intakes 34 Starter Handle 26 Fish Line Trap 35 Primer Knob 27 Propeller 1 36 AC Lighting Inlet 1 Not supplied in all marketing areas General Information 11 ENGINE SPECIFICATIONS 25 30 Models Displacement 31 8 cu in 521 cc Engine Type Two Cycle In line 2 Cylinder Full Throttle Operating Range 25 4500 to 5500 RPM 30 5200 to 5800 RPM Power 1 25 25 HP 18 7 kw 5000 RPM 30 30 HP 22 4 kw 5500 RPM Idle RPM in Gear 2 800 100 Ignition Timing Idle 2 Not Adjustable W O T 30 1 Exhaust Emission Control 2 EM Engine Modification System per SAE J1930 Fuel Requirements 2 87 Pump Posted AKI 89 RON Refer to Fuel and Oil Fuel Oil Ratio 50 1 Ignition Features S L O W Speed Limiting Overheat Warning Starting RL Rope TE TEL Electric start at engine Battery Minimum 360 CCA 465 MCA with 90 minutes reserve capacity OR 50 ampere hour 12 volt Spark Plug 2 Refer to Label Torque 18 to 21 ft Ibs 24 to 28 N m
7. ILLUSTRATIONS AND SPECIFICATIONS VAN WARNING 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 Motor Corporation of America 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 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
8. 2 Fuel connector 1 Emergency stop switch If equipped open vent screw on fuel tank s filler m P Twist the throttle to SHIFT or slower Squeeze fuel primer bulb outlet end up until firm 1 SHIFT Fuel tank operable vent Move the shift lever to NEUTRAL Refer to Shifting 2 Fuel primer bulb and Speed Control VAN WARNING Always shift to NEUTRAL before starting the engine to prevent sudden boat move ment which can cause injury 18 Engine Starting Twist the throttle grip to START 1 START IMPORTANT Avoid engine damage DO NOT run engine above START in NEUTRAL Start up Cold Engine WARNING Start engine with shift lever in NEUTRAL Attempting to manually start the engine while in gear may damage parts or cause the start in neutral only feature to become inoperative Pull primer knob through its full stroke twice and re turn to the warm up color line showing position 1 Primer knob 2 Color line The manual primer has two functions It primes the engine for quick cold starting and provides extra fuel for warm up Rope Start While seated grasp the starter handle and pull slowly until starter engages then pull hard Repeat if needed until motor starts To prevent damage to starter assembly allow starter cord to rewind be fore releasing starter handle If motor does not start refer to Trouble Check Chart dr3754 1 Starter handle 2 NEUTRAL
9. NEUTRAL Electric Start Models WARNING DO NOT use jumper cables and a booster battery to start engine Do not charge a bat tery in the boat with an external charger Fumes vented during either operation can lead to an explosion Tie a knot in one end of your emergency starter cord and hook it in the notch on the flywheel Wind the cord clockwise around the starter ridge on the flywheel making sure the knot clears the starter pinion 1 Knot 2 Starter pinion 3 NEUTRAL All Models Follow the starting procedures in Start up Cold Engine While seated pull hard on emergency starting cord to start motor After the motor starts run it at less than 2000 RPM in NEUTRAL for two minutes then reduce speed to an idle Do not attempt to replace manual starter or engine cover while engine is running If equipped snap emergency stop switch lanyard to a secure place on your clothing Proceed to nearest landing for service FUEL ECONOMY The economy throttle position can save fuel de pending on boat load and hull design When boat reaches top speed throttle back from FULL SPEED You will save fuel without a noticeable loss of speed Engine Starting 23 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
10. 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 Stabilize the engine s fuel supply with 2 4 fuel con ditioner during the last hours of operation to ensure proper stabilization following instructions on the container for mixture Be sure to run the engine long enough for the treated fuel to reach the en gine WARNING Prevent injury from moving engine compo nents Before starting the engine Shift it to NEUTRAL Keep hands clothes and hair clear of pow erhead Remove the propeller if you use flushing device IMPORTANT Provide water supply to the engine and start it Run the engine at idle only To run the engine on a flusher refer to Flushing To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine out of fuel Maintenance 31 S
11. 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 DEALER IMPORTANT The recommended gear lubricants include special additives for marine applications Do not use automotive gear lubricants 2 stroke or 4 stroke engine oil or any other oil or grease for gearcase applications With motor in normal operating position 1 Remove drain fill plug and lubricant level plug from side of gearcase and completely drain gearcase of old lubricant 2 Examine drained lubricant for metal filings milky appearance or black color with burnt odor If old lubricant has any of those charac teristics see your DEALER If drained lubri cant 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 Gearcase Lube dr33673 1 Drainf fill plug 2 Lubricant level plug 3 Shift cradle screw DO NOT REMOVE Maintenance 35 Lubrication Point
12. 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 the waterway bottom Freezing Weather DURING operation in freezing weather keep the gearcase submerged at all times Upon removing your motor from the water leave it in a vertical position until its cooling system is drained IMPORTANT Water that has leaked into the 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 Tilt its gearcase out of the water and Off load all persons into another boat Keep towing speed slower than planing speed Auxiliary Engine When your auxiliary engine is shut OFF shift it to NEUTRAL and
13. remove the propeller and check for debris Clean the shaft and regrease it before rein stalling a propeller Installation Slide thrust washer onto shaft with fish line trap groove facing forward Slide propeller onto shaft engaging the splines and seating it on the thrust washer Slide spacer onto the shaft and engage the propel ler shaft splines Wedge a block of wood between the propeller blade and the antiventilation plate drc3984 Install propeller nut and tighten to a torque of 120 in Ibs 14 38 Maintenance Continue to tighten propeller nut until nut slots and cotter pin hole are aligned Install new cotter pin and bend ends to secure Thrust washer Spacer Propeller nut Cotter pin Remove block of wood Make sure engine is NEUTRAL give propeller a spin It must turn freely 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 of serious damage Fish Line Trap The
14. 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 OIL RATIO New Engine During break in you must use a 25 1 4 oil fuel oil ratio in your fuel tank Refer to Break In 10 Hours Normal Operation After break in the engine must be operated at a 50 1 2 oil fuel oil ratio High Performance During high performance operation you must use a 25 1 4 oil fuel oil ratio in your fuel tank MIXING FUEL AND OIL Use the following chart and these guidelines to mix oil with the engine s fuel 6 U S Gallons 3 U S Gallons 1 Liter 16 fl oz oil 8 fl oz oil 20 ml oil 32 fl oz oil 16 fl oz oil 40 ml oil Portable Tank Above and below 32 F 0 C add one gallon of fu el Pour in required amount of oil Add remaining fu el Install filler cap and tip tank gently to distribute oil Permanently Installed Tank Above 32 F 0 C pour oil slowly with the fuel as tank is filled Below 32 F 0 C add one gallon of fuel to a separate container Pour in required amount of oil Install filler cap and tip container gen tly to distribute oil Slowly pour oil fuel mixture into tank with fuel as tank is filled CO2335 DR3986 Fuel and Oil 15 FUEL SYSTEMS VAN WARNING A If your motor is equipped wit
15. when boating conditions are hazard ous and by children and nonswimmers at all times AN 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 AN Know the marine traffic laws and obey them IN 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 8 reserve fuel supply Do not carry spare fuel or flammable liquids in any storage or engine compartments Do not operate your boat if you are under the influence of drugs or alcohol AN 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 AN For more information see your Evinrude Johnson DEALER for a copy of Introduction to High Performance Boating P N 335763 SAFETY MEASURES Installation and Maintenance Outboard Installation AN The outboard must be correctly installed Fail ure to correctly install the outboard could re sult in serious injury death or property damage We strongly recomm
16. 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 content does not exceed 10 ethanol by volume or 5 methanol with 5 cosolvents by volume 14 Fuel and Oil Minimum Octane Inside the U S Outside the U S 87 R M 2 AKI 89 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
17. Alternator TE TEL 4 Amps Nonregulated AC Lighting 60 watts AC 12 volts Gearcase Lubricant Evinrude Johnson Ultra HPF gearcase lubricant Capacity 12 2 fl oz 361 ml Propeller 4 10 x 13 in 25 x 33 cm Fuel Tank Capacity 6 U S gallons 22 7 liters Weight 117 lbs 53 kg RL 121 Ibs 55 kg 123 Ibs 56 kg TEL 126 Ibs 57 kg Transom Height TE 14 1 2 to 15 in 36 8 to 38 1 cm TEL 19 1 2 to 20 in 49 5 to 50 8 cm Sound at Driver s Ear 82 3 dB A Lpa 39 94 Vibration at Tiller arms Less than 2 5 m s Rated following the standards of ICOMIA 28 83 ISO 3046 and NMMA Emission Control Information 1 2 3 Available as optional 4 Not supplied in all marketing areas 5 Does not include propeller or fuel 12 General Information EMERGENCY STOP SWITCH If equipped the emergency stop switch is on the steering handle Use of the emergency stop feature is highly recommended on all boats Connect the clip to the emergency stop switch Snap the lanyard to a secure place on the 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 or retie the lan
18. ED 22 4 2 PRODUCT REFERENCES ILLUSTRATIONS AND SPECIFICATIONS 2 4 0 44 4 0 4 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2 STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND 5 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2 STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND 4 2 8 FEATURES ENGINE SPECIFICATIONS EMERGENCY STOP SWITCH FUEL AND OIL race VET OIL Re ADDITIVES FUEL OIL RATIO MIXING FUEL AND OIL FUEL SYSTEMS BREAK IN 10 HOURS ENGINE STARTING BEFORE START UP QU PUR QI UNAM D M DR UNUM MU ENGINE STOPPING SHIFTING AND SPEED CONTROL EMERGENCY STARTING A A OPERATION Me UE MOTOR ANGLE ADJUSTMENT TRAILERIN G eee TILTING AND TILT SUPPORT SHALLOW WATER DRIVE PROPELLER SELECTION MOORING FLUSHING ENGINE OVERHEATING IMPACT DAMAGE STORING ET SPECIAL OPERATING CONDITIONS MAINTENANCE Lua iO CU I ROC add zu VON MOI MARI CUu EAR UE Os 10 HOUR INSPECTION OFF SEASON STORAGE PRE SEASON SERVICE BATTERY
19. 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 Bombardier Bombardier reserves the right to modify this warranty at any time being understood that such modification will not alter the warranty conditions applicable to the Products sold while this warranty is in effect 8 TRANSFER If the ownership of Product is transferred during the warranty coverage period this warranty shall also be transferred and be valid for the remaining coverage period provided that the former or new owner promptly contacts Bombardier or Dealer and gives the name and address of the new owner 9 CONSUMER ASSISTANCE Inthe event of a controversy or dispute in connection with this Bombardier limited warranty Bombardier recommends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer s service manager or owner f further assistance is required please contact the Bombardier Customer Support Service
20. Serial Number Purchase Date Ignition Key Number 4 General Information Stolen Outboards North America Report your outboard as stolen to Customer and Dealer Support Services 250 Sea Horse Drive Waukegan IL 60085 U S A Give the outboard s model and serial numbers and enclose a copy of the police report Outside North America Report the theft to the Bombardier distributor where the outboard was reg istered Technical Literature Bombardier Motor Corporation of America offers technical literature specifically for your outboard A service manual a parts catalog or an extra Opera tors Guide can be purchased from your selling DEALER For the name and location of the nearest Evinrude Johnson DEALER in the United States and Canada log on to www evinrude com or www johnson com Declaration of Conformity Bombardier Motor Corporation of America declares that the outboard to which this Operator s Manual applies conforms to the essential requirements out lined in CE Machinery Directive 98 37 EC as amended 23 George Broughton Director of Outboards BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2 STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA 1 SCOPE OF THE LIMITED WARRANTY Bombardier Motor Corporation of America Bombardier warrants its Johnson 2 stroke outboard en gines sold by authorized Johnson dealers in the fifty United States and Canada Product from defects in ma
21. Trim Tab WARNING Improper trim tab adjustment can cause dif ficult steering A propeller will generate steering torque when the propeller shaft is not running parallel to the water s surface The trim tab is adjustable to compensate for this steering torque IMPORTANT A single trim tab adjustment will re lieve steering effort under only one set of speed motor angle and load conditions No single adjust ment can relieve steering effort under all speed motor angle and load conditions If the boat pulls to the left or right when its load is evenly distributed adjust the trim tab as follows With the motor shut OFF loosen the trim tab screw If the boat pulled to the right move the rear of the trim tab slightly to the right If the boat pulled to the left move the rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 60 to 85 in Ibs 7 to 9 N m Test the boat and if needed repeat the procedure until steering effort is as equal as possible High motor installations The trim tab might be above the water when the motor is trimmed out Steering effort might increase Steering effort will be reduced if you trim the motor in and submerge the trim tab 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
22. act with rotating propeller before flushing remove the propeller Top off fuel tank with fresh fuel Battery Charge fully and install Refer to Bat tery Follow Engine Starting and start the engine Let it idle while you Observe running quality if poor refer to Trouble Check Chart or see your DEALER Observe water pump operation Water must flow from the water pump indicator in a steady stream If it does not shut OFF the engine and investigate Refer to Engine Overheating Stop the engine and check the fuel system for leaks WARNING Failure to check for fuel leakage could allow a leak to go undetected resulting in fire or explosion A Each outboard needs one battery that is 12 volt heavy duty designated marine Vented refillable or maintenance free and Rated according to the minimum requirements in Engine Specifications Deep cycle batteries are suitable IF they meet or exceed the minimum CCA requirements Ask your DEALER about your outboard s 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
23. aging shallow water drive Operation 25 Move tilt run lever to the TILT position 1 Tilt run lever TILT position 2 NEUTRAL Grasp tilt grip on engine cover and tilt motor half way Shallow water drive bracket will automatically en gage Slowly lower motor until shallow water drive brack ets 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 26 Operation Disengage Move tilt run lever to the RUN position 1 Tilt run lever RUN position 2 NEUTRAL Grasp tilt grip on engine cover and tilt motor slightly Shallow water drive bracket will automatically re lease Slowly lower motor to normal operating position PROPELLER SELECTION To select the correct propeller for your boating ap plication your boat and motor MUST be water test ed See your DEALER for assistance Refer to Propeller before removing or installing propeller IMPORTANT The correct propeller for your boat under normal load conditions will allow the engine to run near the midpoint of the RPM operating range at full throttle Refer to Engine Specifica tions MOORING You may moor your boat with the motor s gearcase out of the water by using its tilt feature Refer to Tilt ing and Tilt Support FLUSHING DANGER NOT run the engine indoors or without adequate v
24. ctive take them seriously Fail ure to follow this safety information and safe boating rules could result in injury to you your passengers or other water users Become completely familiar with the control and operation of your boat and motor before embarking on your first trip or taking on a 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 op erator you are in control and responsible for safe operation SAFETY MEASURES Operation Be sure at least of your passengers knows how to handle your boat in case of an emergency AA l passengers should know the location of emergency equipment and how to use it AA I 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 Contact with rotating propeller is likely to result in serious injury or death Do not allow anyone near a propeller even when the engine is off Propeller blades can be sharp and can contin ue to turn even after the engine is shut off Al ways shut off the engine when boat is near people in the water Whenever running the engine assure there is proper ventilation to avoid the accumulation of carbon monoxide CO which is odorless col orles
25. current lighting system for operating lights on a boat An AC lighting system is available as an optional kit IMPORTANT Alternating current is generated and MUST NOT be connected directly to a battery For battery charging install a battery charging kit See your DEALER Various combinations of light bulbs can be used Use 12 volt bulbs of wattage sizes indicated on the diagram Follow the illustration for proper installation of wires 40 Maintenance TROUBLE CHECK CHART IMPORTANT If you are unable to identify or solve the problem contact your DEALER SYMPTOM POSSIBLE CAUSE Engine will not start Not following starting instructions Refer to Engine Starting Fuel tank empty Fuel hose disconnected kinked Fuel system contaminated with water or dirt Fuel filter obstructed Cold engine Engine not primed Warm engine Engine flooded Disconnect fuel hose at engine push in choke or primer crank engine If it starts run until cleared If it fails to start wait a few moments and try again Spark plugs incorrect Refer to Engine Specifications Spark plugs improperly gapped carboned burned or wet Ignition system component failure Engine will not idle properly Motor angle excessive Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel system contaminated with water or dirt Carburetor mixture out of adjustment Fuel oil mixture incorrect Engine loses power Spark
26. ection and maintenance Engine Maintenance and Inspection Schedule Frequency o 5 o o gt s 58 ss 88 xc ot o5 oc 55 Ne Engine oo BE BE BS Care rg go oa om EM oc gt gt gt Description Product N Clamp screws lubricate 1 Every 60 days Every 30 in Saltwater N Tilt tube tilt lever shaft lubricate 1 Swivel bracket tilt support bracket lubricate 1 Every 60 days Every 30 in Saltwater N Every 60 days Every 30 in Saltwater N Shift lever shaft shallow water drive bracket Every 60 days Every 30 in Saltwater inspect and lubricate Engine cover latch lubricate i Every 60 days Every 30 in Saltwater Throttle and shift linkage lubricate 1 Every 60 days Every 30 in Saltwater N Carburetor linkage starter lockout inspect Every 60 days Every 30 in Saltwater and lubricate 1 Anticorrosion anodes verify operation Water intake screens verify condition Overboard water pump indicator verify operation Steering system check verify function Throttle and shift operation verify function Emergency stop circuit and lanyard verify function Flush cooling system Emergency Start Cord onboard and inspect Operator s Guide onboard Clamp screws tighten e ee Engine upper and lower motor covers clean O and wax Operator s Guide review O Fuel filter inspection el
27. end that your DEALER install your outboard to ensure prop er installation AN 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 AN When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Using substandard parts could result in injury or product malfunc tion 4A Only perform service procedures which are detailed in this Operators 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 per sonal injury or death Further information can be obtained from your authorized Evinrude Johnson DEALER In many instances proper tools and training are required for certain ser vice or repair procedures AN Maintain your boat and engine in top condition at all times Adhere to the Engine Mainte nance and Inspection Schedule Z Operate your boat and outboard prudently and have fun Do not forget that all persons must assist other boaters in case of emergen cy AN Prevent injury from contact with rotating pro peller remove propeller before flushing or be fore performing any maintenance General Information 3 PRODUCT REFERENCES
28. entilation or permit exhaust fumes to accumulate in confined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death See your DEALER for a flushing device designed to fit your engine Follow manufacturer s instructions for installing and using it Outboard Running WARNING Prevent injury from contact with rotating propeller remove the propeller before flushing 1 Place the engine in vertical position in a well ventilated area with good drainage 2 Cover the two small holes on each side of the gearcase with heavy tape to make sure enough water will travel to the powerhead Remember to uncover the holes after flush ing the engine dr4918 Gearcase holes Water intakes Install flushing device and garden hose Place the shift lever in NEUTRAL with the propeller removed Start the water keep pressure between 20 to 40 psi 140 to 300 kPa 2 drc44684 drc4952arev 7 Flushing device Water pump indicator 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 Leave the outboard in vertical position long enough to completely drain the powerhead Operation 27 ENGINE OVERHEATING IMPORTANT Do not run your engine even
29. expected 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 powerhead Prevent electric shock by keeping clear of the ignition coils and spark plug leads when the motor is being started or is running Shock can cause serious personal injury under certain conditions DO NOT turn flywheel by hand Use starter cord only Engine Starting 21 Move tilt run lever to RUN position Place motor its normal operating position 1 RUN position Be sure Engine is in normal operating position Fuel hose primer bulb is firm Shift lever is in NEUTRAL Twist Grip throttle is at START Pull latch and remove engine cover 22 Engine Starting Manual Start Models Remove three screws that secure the manual start er and remove starter assembly from engine 1 Screws Using a screwdriver compress one of the two lock ing tabs on the starter lockout cable At the same time pull the cable steadily until that tab clears the housing Repeat for the other locking tab Pull the lockout cable from the starter housing Secure the lockout cable in the lower engine cover away from moving engine parts 1 Locking tabs a knot one end of your emergency starter cord and hook it in the notch on the flywheel Wind the cord clockwise around the starter ridge on the flywheel 1 Knot 2
30. for a brief start up without supplying water to it Refer to Flushing While boating the engine s water intakes must stay completely submerged and unobstructed Observe proper transom height and trim angle While the 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 DRC4952rev 1 Water intake screens 2 Water pump indicator If the engine overheats the S L O W Speed Limit ing Overheat Warning protection system will im mediately limit the engine speed to 2000 RPM If the engine was running faster than 2000 RPM when the S L O W system activated it will shake noticeably To RESET the S L O W protection system the en gine must be shut OFF and the cooling temperature restored 28 Operation IF the S L O W protection system activates and the stream from the water pump indicator becomes in termittent or stops reduce speed to idle and Shift to NEUTRAL SHUT OFF the engine Tilt the motor up Clean the intake screens and four small gearcase holes of any blockage Clean the water pump indicator of any blockage Lower the motor and Restart the engine and run at idle IF cleaning the screens and indicator does not re store the water pump indicators steady discharge SHUT OFF the en
31. gine and do not attempt to oper ate it See your DEALER IF cleaning the screens and indicator does restore the water pump indicators steady discharge you might have to run for two minutes in NEUTRAL to allow the engine to cool IMPORTANT You must restore cooling to the 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 IMPACT DAMAGE Your engine has a shock absorption system de signed to help withstand damage from impact with underwater objects at low to moderate speeds However high speed impacts with rigid underwater objects like pilings or boulders can be beyond the capability of the absorption system Such impacts can result in serious damage to your engine and 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 seri
32. gn material Damage resulting from sand or debris in the water pump Cosmetic or paint changes due to exposure to the elements This warranty will be voided in its entirety and rendered null and void where Product has been altered or modified in such a way so as to adversely affect its operation performance or durability or change its intended use horsepower or emission levels or Product is or has been used for racing at any point even by a prior owner 6 General Information 7 LIMITATIONS OF LIABILITY ALL WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION ANY 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 reinstallation mechanic s travel time in and out of water charges slip or dock fees trailering or towing storage telephone cell phone fax or telegram charges rental of a like or replacement Product or boat during warranty services or down time taxi travel lodging loss of or damage to personal property inconvenience cost of insurance coverage loan payments loss of time loss of income revenue or prof its or loss of enjoyment or use of Product
33. h a curved transom these guidelines might not apply See your DEALER for special installation in formation Installing the Engine WARNING The outboard must be correctly installed Failure to correctly install the outboard could result in serious injury death or prop erty damage We strongly recommend that your DEALER install your outboard to ensure proper installation IMPORTANT Follow all directions carefully The engine s warranty will not cover product damage or failure that results from incorrect engine installation WARNING Even if equipped with clamp screws your engine must be bolted to the boat to prevent it from working off the transom during operation Center the engine on the boat s transom or mount ing bracket and tighten the clamp screws by hand NOT with tools See your DEALER for an accesso ry transom plate to protect the boat s transom Maintenance 47 Bolt your engine to the boat s transom using the mounting hardware provided 1 Clamp screws 2 Transom plate 3 Upper stern bracket holes After positioning the engine use the stern brackets as a template for location and size of holes to drill in the transom 48 Maintenance The stern bracket has two holes on each side of the engine Drill only one hole on each side Use the upper holes unless your situation requires using the lower holes Be sure to drill at right angles to the tra
34. h 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 in 8 mm Fuel systems with built in tanks particularly those that include antisiphon valves and filter primer units may have restrictions that will not allow the engine fuel pump to deliver sufficient fuel under all conditions This can result in a loss of performance and possible engine damage If a performance problem exists see your DEALER To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine out of fuel BREAK IN 10 HOURS IMPORTANT Follow this procedure to protect your new outboard during its initial hours of operation Careful break in allows internal engine components to seat properly resulting in maximum engine per formance Failure to carefully follow the break in procedures can result in engine damage During break in you must use extra oil The fuel oil ratio for the first 10 hours of operation must be 25 1 4 oil The fuel oil ratio during normal operation after break in must be 50 1 2 oil Perform the 10 Hour break in procedure with the boat and engine i
35. his dimension is measured at the transom centerline perpendicular to the bottom of the boat 1 Transom height 2 Antiventilation plate 3 Final position O to 2 in 0 to 51 mm Use this procedure to determine whether or not the boat s transom height is correct for the engine s shaft length Lift the engine using the lift grips NOT the tilt grip or steering handle and place it in the center of the boat s transom 1 Lift grips If equipped tighten clamp screws by hand NOT with tools Adjust the motor angle so the antiventilation plate is parallel with the boat bottom Refer to Motor Angle Adjustment The resulting position of the antiventilation plate must be no higher than the boat s bottom and no lower than 2 in 5 1 cm below it If the resulting position of the antiventilation plate is above or below the 0 to 2 in 0 to 5 1 cm range the engine shaft length must be changed or the boat s transom must be modified If you install and operate the engine Lower than recommended Serious powerhead damage could result from water entry into the lower engine cover or overloading from an under revving propeller at wide open throttle Higher than recommended Serious powerhead damage could result from inadequate cooling or an over revving propeller Propeller ventilation slip page often occurs resulting in poor boat perfor mance On a specialty hull non planing hull or on a boat wit
36. ignature Date New address New owner Last name First name Address Zip code City Phone number Signature Date 000063 Maintenance 49 50 Maintenance BOMBARDIER Pe RECREATIONAL PRODUCTS E s EVINRUDE JOHNSON DEALER SUPPORT SERVICES 250 SEAHORSE DRIVE WAUKEGAN IL 60085 000064 Operator s Guide Confirmation of Receipt Your DEALER Name Address Upon delivery of your new Evinrude Johnson Outboard complete and sign the form hereunder Your DEALER will take receipt of the form for their records Receipt Name Address Owner of Model No Serial No To be completed by customer or selling DEALER The DEALER named on this document has instructed me on the operation maintenance safety features and warranty policy all of which understand and agree to be bound with 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 Maintenance 51 BOMBARDIER RECREATIONAL PRODUCTS P am BOMBARDIER s 52 Maintenance Readiness Test and 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
37. iminate contamination D Fuel system components inspect and repair 5 leaks 42 Maintenance Engine Maintenance and Inspection Schedule Description Fastener inspection tighten loosened components Thermostat inspect and verify operation 2 Engine Care Product Each Use 10 Hour Inspection Frequency Every 200 Hours or Biannually 5 os lt gt Every 50 Hours or 6 months Engine to transom mounting hardware torque Electrical and ignition wires connections inspect Gearcase lubricant replace Powerh ad synchronization and linkage inspect 2 Gearcase lubricant inspect fill level and condition of lube Starter pinion shaft inspect and lubricate 3 Propeller shaft splines inspect and lubricate Spark plugs replace 2 Decarbonize Driveshaft splines inspect and lubricate Water pump inspect and replace 1 Also recommended at 10 Hour Inspection 2 Emission related component 3 Do not use light duty penetrating lubricants Dealer Performed Service Operator Performed Service Ultra HPF gearcase lubricant Power Trim Tilt Fluid Triple Guard frease 0o 400 5 OU Starter Bendix Lube Only P N 337016 Evinrude Johnson Engine Tuner Evinrude Johnson Moly Lube P N 175356 Evinrude Johnson anti corrosion spray or E
38. ion process has been com pleted and documented by the purchaser and Dealer Warranty coverage only becomes available upon proper registration of Product by Dealer or owner Only the original purchaser and any subsequent owners who reside in the United States and Canada and have purchased Product from a U S or Canadian Dealer are eligible for warranty registration and warran ty coverage hereunder Such limitations are necessary in order to allow Bombardier to protect the safety of its products its consumers and the general public As outlined in the Operator s Guide timely routine required maintenance must be performed to maintain warranty coverage Bombardier may require proof of proper maintenance prior to authorizing warranty coverage 4 WHAT TO DO TO OBTAIN WARRANTY COVERAGE The registered owner must notify an authorized Dealer within two 2 days of the appearance of a defect Owner must bring Product including any defective part therein to Dealer promptly after the appearance of the defect and in any event within the warranty period and must provide Dealer with reasonable 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 re
39. ion 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 2333 1 Ribbed portion of the spark plug Maintenance 37 PROPELLER WARNING When servicing the propeller always shift the outboard to NEUTRAL position and twist and remove all spark plug leads so the engine cannot be started accidentally IMPORTANT Apply Triple Guard grease to the en tire propeller shaft before installing the propeller At least annually
40. is a quick disconnect If not and the hose is se cured to the engine leave it connected Secure the hose to protect it WARNING Store fuel tanks in a well ventilated area away from heat and open flame Prevent escape of liquid or vapors which could acci dentally ignite Close the filler cap vent screw if equipped Be sure the discon nected fuel hose does not drip 32 Maintenance 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 VAN WARNING 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 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 VAN WARNING Prevent injury from cont
41. keep its gearcase out of the water by tilting it fully or raising the mounting bracket 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 WARNING 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 A Tampering with the carburetor to change horse power or modify emission levels beyond factory settings or specifications will void the product war ranty 10 HOUR INSPECTION After 10 hours of operation your new engine will be broken in and its mechanical parts will have seated At that time all systems should be checked and any adjustments needed should be made Your DEALER will perform this 10 Hour Inspection at your request and expense based on local rates according to what your engine needs refer to 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
42. n the motor could tilt into the boat suddenly causing loss of control or serious injury IMPORTANT Use the tilt grip to tilt your motor not the steering handle Tilt UP Move tilt run lever to TILT position 1 Tilt run lever TILT position Grasp tilt grip on engine cover and tilt motor to the full tilt position Tilt support will automatically engage 1 Tilt grip WARNING While engine is tilted leave tilt lever in the TILT position When the tilt run lever is in the RUN position tilt support can release unexpectedly and allow motor to drop A Tilt DOWN Move tilt run lever to RUN position 1 Tilt run lever RUN position Grasp tilt grip on engine cover and raise motor slightly Tilt support will automatically disengage Slowly lower motor to its normal operating position SHALLOW WATER DRIVE WARNING When in shallow water drive your motor has no protection from the effects of under water impact Operate your motor in FORWARD and ONLY at slow speed The motor can tilt up forcibly and drop suddenly if it hits an underwater object or if you shift to REVERSE and apply throttle You could lose control The motor s 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 diseng
43. n the water using an appropriate propeller DO NOT perform break in using a flushing device DO NOT start up or run the engine out of the water DO NOT leave a running engine unattended 16 Fuel and Oil IMPORTANT Before the first start up of your new engine Read Engine Starting Engine Stopping and Shifting and Speed Control Check the gearcase lube level Refer to Lubrica tion Perform prelaunch checks of all equipment Launch the boat and start the engine according to the procedures in Engine Starting Verify water pump operation often Look for a steady stream of water from the water pump 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 Refer to Shifting and Speed Control Change the RPM often Avoid holding a throttle setting longer than 15 minutes 1 First 10 Minutes of Operation Operate the engine in gear at fast idle only 2 Next 50 Minutes Operate engine in gear at various speeds no faster than 3500 RPM DO NOT hold a constant throttle setting Change engine speed every 15 minutes With easy planing boats use full throttle to quickly accelerate boat onto plane Immediately reduce throttle to one half as soon as boat is on plane BE SURE boat
44. ne 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 Damage caused by improper or lack of installation maintenance winterization and or storage failure to follow the procedures and recommendations in the Operator s Guide Damage resulting from removal of parts improper repairs service maintenance or modification or use of parts or accessories not manufactured or approved by Bombardier which in its reasonable judgment are either incompatible with Product or adversely affect its operation performance or durability or re sulting from repairs done by a person that is not an authorized Dealer Damage caused by abuse misuse abnormal use neglect racing improper operation or operation of anes in a manner inconsistent with the recommended operation described in the Operator s uide Damage resulting from external damage accident submersion water ingestion fire theft vandalism or any act of God Operation without proper fuel oil or lubrication or with fuels oils or lubricants which are not suitable for use with the Product see the Operator s Guide Damage resulting from rust or corrosion Damage caused from cooling system blockage by forei
45. nsom Apply polysulfide sealant generously behind the heads and to the shanks of the mounting bolts be fore inserting them and to the surfaces of washers that contact the transom Avoid RTV silicone and polyurethane sealants as they can be dissolved by gasoline Secure the engine with the mounting hardware After 30 minutes of operation retighten clamp screws by hand DO NOT use tools to tighten clamp screws Check clamp screws regularly WARNING When replacing bolts screws or other fas teners use Johnson parts or parts of equiv alent strength and material CHANGE OF ADDRESS CHANGE OF OWNERSHIP If your address has changed or if there has been a change of ownership be sure to fill out and mail the card provided on this page Such notification is likewise necessary for your own safety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your outboard becomes necessary Outside the U S and Canada this card should be sent to the Bombardier division where the outboard was registered Please contact your Dealer or Distributor Change of address Change of ownership ie Model number Serial Number Old address Previous owner Last name First name Address State Zip code City Phone number S
46. on which if not avoided CAN result in severe injury or death CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate personal injury or property 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 2 General Information A responsible educated boater will fully appreciate the pleasures of boating and will be a safe boater Boating Safety Classes are conducted by the U S Coast Guard Auxiliary the U S Power Squadron and some Red Cross Chapters For information about classes call toll free 1 800 336 BOAT For additional information about boating safety and reg ulations call U S Coast Guard Boating Safety Hot line 1 800 368 5647 Outside North America please contact your DEALER or distributor for de tails 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 followed by any boater Some rules may be new to you and others may be common sense or obvi ous irrespe
47. ontinue to turn even after the engine is off Always shut off the engine when near people in the water BEFORE START UP Review and follow Break In 10 Hours if the en gine is new You MUST supply water to the engine before at tempting to start it Engine damage can occur quickly Refer to Engine Overheating or Flushing Move tilt run lever to RUN Be sure the engine is in normal operating position Refer to Tilting and Tilt Support dr4407a 1 RUN position If you will be using a battery connect it as instructed in Battery Electric start models can be started manually and operated without a battery WARNING When not connected to a battery cover the positive battery cable s ring terminal with the attached boot to prevent the charg ing system from sparking Do not wrap the loose battery cable around the engine as a way of storing it Doing so can restrict steering or damage the cable or both Loop the cable and hang it close to the engine Do not connect electrical equipment to the engine s charging system The connected equipment and the engine could both be damaged dr5826 Positive battery cable boot Engine Starting 17 Connect the fuel hose to the fuel connector If equipped attach the clip and lanyard assembly to the emergency stop switch Snap the lanyard to se cure place on your clothing or life vest dr3927 1 Fuel hose connector
48. ously 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 components WARNING VN Failure to inspect for damage could result in sudden unexpected component failure loss of boat control and personal injury Unrepaired damage could reduce your boat and engine s ability to resist future impacts STORING To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine out of fuel If you must tilt the motor to remove it from the water lower it and allow the cooling system to drain 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 Operation 29 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 Refer to Flushing During use in salt or brackish water additional an odic protection fo
49. outboard WARNING Leaking fuel is a fire and explosion hazard All parts in the fuel system should be inspected frequently and replaced if signs of deterioration or leakage are found Inspect the fuel system each time you refuel each time you remove the engine cover and annually OIL Evinrude Johnson XD25 formula outboard oil is recommended for your outboard It contains a richer additive package than other TC W3 oils min imizing carbon build up and deposits on pistons and bearing surfaces It provides 25 greater de tergency than minimum requirements Evinrude Johnson brand oils are formulated to give best engine performance while controlling piston and combustion chamber deposits providing supe rior lubrication and ensuring maximum spark plug life If Evinrude Johnson XD25 formula outboard oil is not available you must use an NMMA certified TC W3 oil such as Evinrude Johnson direct injection or Evinrude Johnson biodegradable outboard oil 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 Bombardier for your outboard Use of other fuel ad ditives 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
50. pair in order to validate the warranty repair All parts replaced under this warranty become the property of Bombardier General Information 5 5 WHAT BOMBARDIER WILL DO Bombardier s obligations under this warranty are limited to at its sole discretion repairing or replacing parts of Product found to be defective in material or workmanship in the reasonable judgment of Bombar dier Such repair or replacement of parts will be done without charge for parts and labor at any authorized Dealer Bombardier s responsibility is limited to making the required repairs or replacements of parts with new or Bombardier certified re manufactured parts No claim of breach of warranty shall be cause for can cellation or rescission of the sale of Product to owner In the event that warranty service is required outside of the fifty United States or Canada owner will bear responsibility for any additional charges due to local practices and conditions such as but not limited to freight insurance taxes license fees import duties and any and all other financial charges including those levied by governments states territories and their respective agencies Bombardier reserves the right to improve modify or change Products from time to time without assuming any obligation to modify Products previously manufactured 6 EXCLUSIONS The following are not warranted under any circumstances Replacement of parts due to normal wear and tear Routi
51. people around 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 VAN WARNING VAN Be careful Human error is caused by many factors carelessness fatigue overload preoccu pation unfamiliarity of operator with the product drugs and alcohol to name a few Damage to your boat and outboard can be fixed in a short period of time but injury or death has a lasting effect For your safety and the safety of others read this Guide from cover to cover and follow all safety warnings and recommendations Do not disregard any of the safety precautions and instructions Anyone operating your boat should first read and understand this Guide before they operate your boat and motor The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates 2440 fuel conditioner Renegade bass CarbX S L 0 W Evinrude SST Evinrude Johnson anti corrosion spray System Check Evinrude Johnson Genuine Parts Touch Trim Evinrude Johnson XD25 formula Triple Guard grease Hi Vis gearcase lubricant Twist Grip Johnson Ultra HPF gearcase lubricant QuikStart Viper Contents GENERAL INFORMATION 255 2 SAFETY THE RIGHT PLACE START
52. 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 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 S L O W protection mode activated Refer to Engine Overheat ing Carburetor mixture out of adjustment Steering friction screw loose if so equipped Engine runs but makes little or no progress Propeller hub loose slipping Propeller blades bent or missing Propeller shaft bent Propeller fouled and restricted Maintenance 41 ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products Periodic maintenance contributes to the product s life span The following maintenance chart provides guidelines for engine maintenance and in spection scheduled to be performed by you and or by an authorized DEALER The schedule should be adjusted according to operating conditions and use The recommended lubricants have been formulated to protect bearings gears and engine components They must be used to avoid damage caused by improper lubrication IMPORTANT Schedules for rental operations commercial applications or high hour use will require greater frequency of insp
53. r 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 vibration and reduce boat speed Run at slow speeds and in REVERSE frequently to clear weeds from the propeller and water intakes Check the water pump indicator often If REVERSE operation does not clear away weeds SHUT OFF the engine Remove weeds from 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 corro sion 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 30 Operation High Altitude If you boat at altitudes above 3000 ft 900 m your engine might benefit from a lower pitched propeller
54. remains on plane at this throttle setting 3 Second Hour Use full throttle to accelerate boat onto plane then reduce throttle setting to three quarters BE SURE boat remains on plane at this throttle setting At intervals apply full throttle for periods of one to two minutes returning to three quarters throttle for a cooling period Change engine speed every 15 minutes 4 Next Eight Hours Avoid continuous throttle operation for extended periods Change engine speed every 15 minutes DO NOT exceed recommended maximum engine RPM Refer to Engine Specifications full ENGINE STARTING DANGER NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death WARNING The engine cover is a machinery guard DO NOT operate your outboard with the cover off unless you are performing maintenance and then be careful to keep hands hair and clothing clear of all moving parts Contact with moving parts could cause injury DANGER Contact with a rotating propeller is likely to result in serious injury or death Assure the engine and prop area is clear of people and objects before starting engine or operating boat Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can c
55. s Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom mended lubricant 1 Throttle linkage 2 Engine cover latch 1 Tilt tube clamp screws 2 Tilt lever shaft 1 Shallow water drive bracket tilt support swivel bracket 1 Shift lever shaft 36 Maintenance FUEL PUMP FILTER The fuel filter is located in the motor s fuel pump An authorized Evinrude Johnson DEALER should ser vice the fuel filter WARNING Prevent excessive fuel spillage by discon necting fuel hose from motor before disas sembly A The filter is located under the inlet cover on the fuel pump To service proceed as follows If portable tank is used disconnect the fuel hose from the motor before servicing the filter Loosen screw and remove the cover Do not lose O rings 1 Cover 2 Filter 3 O rings Wash filter with clean solvent blow dry Reinstall filter keeping lip of filter screen toward fuel pump body Install large O ring in its groove in the cover and the small O ring around center post of pump body Replace O rings if cut or damaged Reinstall cover Tighten cover screw securely clean up spilled fuel Check for leaks connect fuel hose to motor and squeeze primer bulb until firm WARNING Failure to inspect your work could allow fuel leakage to go undetected becoming a fire or explosion hazard SPARK PLUGS VAN WARNING The ignit
56. s 250 Sea Horse Drive Waukegan IL 60085 1 847 689 7090 Revision April 2003 Engines sold in Canada are distributed and serviced by Bombardier Inc General Information 7 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2 STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA For a copy of the Limited Warranty see your Bombardier distributor dealer authorized to distribute Johnson 2 stroke products in the country in which the sale occurs If further assistance is required please contact Bombardier Customer Support Services 250 Sea Horse Drive Waukegan Illinois 60085 or the affiliate of Bombardier where the Product was registered for war ranty 8 General Information NOTES General Information 9 FEATURES Electric Start Models 7 WU 000152 6 1 8 000147 Description Item Description 1 Fuel Pump Filter 10 Positive Terminal Boot 1 2 Water Pump Indicator 11 Battery Cable 1 3 Steering Friction Screw 12 Clip and Lanyard Assembly 4 Tilt Run Lever 13 Stop Button Emergency Stop Switch 5 Angle Adjusting Rod 14 Emergency Restart Clip Storage 6 Lubricant Drain Fill Plug 15 Shift Lever 7 Lubricant Level Plug 16 Electric Start Button 0 8 Shallow Water Drive Bracket 17 Electric Starter 1 9 Clamp Screws 18 Emergency Start Cord 1 Electric Start Models 10 General Information Manual Rope Start Models
57. s and tasteless and can lead to uncon sciousness brain damage or death if inhaled in sufficient concentrations CO accumulation can occur while docked anchored or under way and in many confined areas such as the boat cabin cockpit swim platform and heads It can be worsened or caused by weather mooring and operating conditions and other boats Avoid exhaust fumes from your engine or other boats provide proper ventilation shut off your engine when not needed and be aware of the risk of backdrafting and condi tions that create CO accumulation In high concentrations CO can be fatal within min utes Lower concentrations are just as lethal over long periods of time A Proceed with caution and at very low speed in shallow water Grounding or abrupt stops may result in personal injury or property damage Also be alert for debris and objects in the wa ter AN 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 obstructions Contact with underwater obstructions may re sult in loss of control and personal injury Avoid standing up or shifting weight suddenly in light weight boats ZN Keep your passengers seated in seats The boat s bow gunwale transom and seat backs are not intended for use as seats IN Insist on the use of personal flotation devices approved by the U S Coast Guard by all pas sengers
58. 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 how ever your understanding of and adherence to essential information contained in this Guide will build good judgment when boating Always be alert and careful a good foundation for safety
59. 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 TWENTY FOUR 24 CONSECUTIVE MONTHS for private recreational use or TWELVE 12 CONSECUTIVE MONTHS for commercial use The Product is used commercially when it is used in connection with any work or employment that generates income during any part of the warranty period The Product is also used commercially when at any point during the warranty period it is installed on a boat that has commercial tags or is licensed for commercial use The repair or replacement of parts or the performance of service to Product under this warranty does not extend the life of this limited warranty beyond its original expiration date All Evinrude amp Johnson Genuine Parts and accessories installed by an authorized dealer at the time of sale including but not limited to pro pellers bear the standard Bombardier parts and accessories one year limited warranty 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on Johnson 2 stroke outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred Dealer and then only after the Bombardier specified pre delivery inspect
60. thrust bushing contains a built up groove as a trap for fish line Every 15 to 20 hours of operation or whenever you suspect the presence of fish line remove the propeller and check the trap Remove any debris 1 Fish line trap groove IMPORTANT Fish line can damage propeller shaft seals Damaged seals can allow water to enter the gearcase causing internal damage 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 replacements dr4419 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 Maintenance 39 AC LIGHTING TE 66 6 666 Le 1 Sleeve 2 Electrical tape covering connection 3 Light bulb Y Yellow wire YG Yellow Grey wire YB Yellow Blue wire Some models have an AC alternating
61. torage Fogging Oil Following instructions on the can fog the engine 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 Fuel filter Clean Screws bolts nuts Tighten that are loose any Propeller Remove and examine If damaged see your DEALER Clean the propeller shaft and lu bricate it Refer to Propeller Lubrication Refer to Lubrication to drain and refill the gearcase and for lubricating points on the engine Touch up painted surfaces and wax the engine s exterior Store the engine on the boat or an engine stand in a vertical self draining position IMPORTANT Never place the gearcase higher than the powerhead Any water remaining in the ex haust passages can run into the cylinders and cause serious damage If you remove an installed engine examine all hardware you loosened or removed from the en gine and its steering throttle and shift systems Replace damaged or missing parts with Evinrude Johnson Genuine Parts or equivalent Battery Remove it clean it check its condition and water level then charge it Store it in a place that s cool and dry out of direct sunlight Check the water level and charge it periodically during the storage period Portable fuel tank Disconnect the hose from the tank Remove the hose from the engine if the fit ting
62. vent screw on the fuel tank s filler cap 1 STOP button To avoid difficulty when restarting never stop the engine by running it with the fuel hose disconnected or otherwise running it out of fuel SHIFTING AND SPEED CONTROL IMPORTANT Carefully check the function of all control and engine systems before leaving the dock DO NOT shift the engine into FORWARD or REVERSE while it is shut OFF Shifting With the engine running twist the throttle grip to SHIFT or slower Move the shift lever briskly and decisively to FOR WARD or REVERSE 1 Shift lever 2 FORWARD 3 REVERSE WARNING A Do not operate motor in REVERSE with the tilt run lever in TILT Motor may tilt out of the water resulting in loss of control IMPORTANT Before moving the shift lever reduce throttle to SHIFT speed or slower then pause until motor slows to idle speed and boat has slowed Speed Control With the engine running twist the throttle grip Counterclockwise to increase speed or Clockwise to decrease speed 1 Decrease speed 2 Increase speed EMERGENCY STARTING If the starter cord breaks or the starter fails your en gine can be started using a piece of the starter cord or a 1 4 in 6 mm cord about 4 ft 1 2 m long AN WARNING 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 un
63. vinrude Johnson 6 in 1 multi purpose lubricant Maintenance 43 NOTES 44 Maintenance BOMBARDIER RECREATIONAL PRODUCTS BOMBARDIER ee Maintenance 45 INSTALLATION VAN 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 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 is 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 1 2 in 38 mm and 2 1 4 in 57 mm in thickness 46 Maintenance Transom Height and Shaft Length The transom height dimension listed in Engine Specifications is the height of the boat transom your engine needs T
64. y part of the body immediately flush with water and seek medical attention Maintenance 33 ADJUSTMENTS Idle Speed The idle speed adjusting knob is located at the end of the steering handle Before turning the knob be sure the throttle is at SLOW and the motor has reached normal operating temperature Increase idle speed turn knob clockwise Decrease idle speed turn knob counterclock wise 1 Idle speed adjusting knob If your engine displays poor running quality at idle ask your DEALER to perform the necessary adjust ments Carburetor High speed fuel calibration is maintained by the fixed high speed jet in the carburetor Fixed jets are not adjustable Low speed fuel calibration is set at the factory with a range of adjustment provided If your engine dis plays poor running quality at low speed or idle ask your DEALER to perform the necessary adjust ments Steering Friction The steering friction was set on your new motor be fore it left the factory 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 or Counterclockwise to decrease friction 34 Maintenance 1 Steering friction adjustment screw WARNING DO overtighten for hands off steer ing Reduced steering control could result
65. yard 1 Ws i _ 2 dr3968 Emergency stop switch Clip An extra clip is provided another person can in sert it in the stop switch and start the motor in an emergency dr3969 1 Extra clip WARNING A Avoid knocking or pulling the clip off the stop switch during normal boating The resulting unexpected loss of forward motion can throw occupants forward caus ing 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 General Information 13 FUEL AND OIL FUEL VAN WARNING Gasoline is extremely flammable and highly explosive under certain conditions Follow the instructions in this section explicitly Improper handling of fuel could result in property damage serious injury or death Always turn off the engine before fueling Never permit anyone other than an adult to refill the fuel tank Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun Remove portable fuel tanks from the boat before fueling Always
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