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WARNING Read this Operator Guide thoroughly. It contains important safety information. When operating your boat, always have this Operator Guide onboard. ! ! PL4, PX4, X4, CX4 4 Stroke 90/115/140 HORSEPOWER 2005

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Page 1: Johnson 140

*5035765* WARNINGRead this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always have this Operator Guide onboard.

! !

PL4, PX4, X4, CX4

4 Stroke90/115/140 HORSEPOWER

2005

Page 2: Johnson 140

Our First Words to the Owner/OperatorThis Operator’s Guide is an essential part of your Johnson outboard. It contains pertinent informationwhich, 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 isstrongly 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 anypassengers and other boaters. An Operator’s Readiness Test has been prepared on the last page of thisGuide.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 forthe 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 LawAgency.The pleasures of owning and operating a Johnson outboard can be significant. We strongly believe therewards for following our recommendations will be worthwhile. Remember that YOU are the key to safety.Good safety practices not only protect you but also protect the people around you.Having fun is what it’s all about and, with your cooperation, the pertinent information in this Guide can en-sure a safe and enjoyable experience.Enjoy the great outdoors on the water...

The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates:

WARNINGBe 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 toyour boat and outboard can be fixed in a short period of time, but injury or death, has a lastingeffect.

For your safety and the safety of others, read this Guide from cover to cover and follow allsafety warnings and recommendations. Do not disregard any of the safety precautions andinstructions.

Anyone operating your boat should first read and understand this Guide before they operateyour boat and motor.

Evinrude® Johnson®

Evinrude®/Johnson® Genuine Parts Hi-Vis™ gearcase lubricant

Evinrude®/Johnson® 4-Stroke outboard oil S.L.O.W.™

Evinrude®/Johnson® Ultra™ 4-Stroke synthetic blend oil SystemCheck™

Evinrude®/Johnson® anti-corrosion spray Triple-Guard® grease

2+4® fuel conditioner Ultra-HPF™ gearcase lubricant

99011-90J04-BBD

0 -

Page 3: Johnson 140

Contents

GENERAL INFORMATION ................................................................................................... 2SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON

4-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ..................................... 5BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON

4-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ......................... 8CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 9FEATURES ............................................................................................................................................................... 12ENGINE SPECIFICATIONS ...................................................................................................................................... 14ENGINE SPECIFICATIONS ...................................................................................................................................... 15REMOTE CONTROL ................................................................................................................................................. 16

ENGINE MONITORING ...................................................................................................... 18FUEL AND OIL ................................................................................................................... 19

FUEL ......................................................................................................................................................................... 19OIL ............................................................................................................................................................................. 20ADDITIVES ................................................................................................................................................................ 20FUEL SYSTEM .......................................................................................................................................................... 20BREAK-IN (10 HOURS) ............................................................................................................................................ 21

ENGINE STARTING ........................................................................................................... 22BEFORE START-UP ................................................................................................................................................. 22ENGINE STOPPING ................................................................................................................................................. 23SHIFTING AND SPEED CONTROL ......................................................................................................................... 24FUEL ECONOMY ...................................................................................................................................................... 25

OPERATION ....................................................................................................................... 26POWER TRIM AND TILT .......................................................................................................................................... 26PROPELLER SELECTION ....................................................................................................................................... 29MOORING ................................................................................................................................................................. 29FLUSHING ................................................................................................................................................................ 29ENGINE OVERHEATING .......................................................................................................................................... 31TRAILERING ............................................................................................................................................................. 32TILT SUPPORT ......................................................................................................................................................... 32IMPACT DAMAGE .................................................................................................................................................... 33STORING .................................................................................................................................................................. 33SPECIAL OPERATING CONDITIONS ..................................................................................................................... 34

MAINTENANCE .................................................................................................................. 35ENGINE EMISSIONS INFORMATION ...................................................................................................................... 3510-HOUR INSPECTION ............................................................................................................................................ 36OFF-SEASON STORAGE ........................................................................................................................................ 36PRE-SEASON SERVICE .......................................................................................................................................... 38BATTERY .................................................................................................................................................................. 39CRANKCASE OIL AND FILTER .............................................................................................................................. 40ADJUSTMENTS ........................................................................................................................................................ 41LUBRICATION .......................................................................................................................................................... 42WATER PRESSURE ................................................................................................................................................. 44FUEL LINE FILTER ................................................................................................................................................... 44FUSES ....................................................................................................................................................................... 44SPARK PLUGS ......................................................................................................................................................... 45PROPELLER ............................................................................................................................................................. 45ANTICORROSION ANODES .................................................................................................................................... 46BONDING WIRES ..................................................................................................................................................... 47MOTOR REMOVAL AND TRANSPORTING ............................................................................................................ 47TROUBLE CHECK CHART ...................................................................................................................................... 48ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 50

© 2004 Bombardier Motor Corporation of America. All rights reserved.TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

1

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GENERAL INFORMATION

SAFETY — THE RIGHT PLACE TO GET STARTED

This Operator’s Guide contains essential informa-tion to help prevent personal injury and damage toequipment. It will acquaint the operator and pas-sengers with the Evinrude/Johnson outboard andits controls, operation, maintenance and boatingsafety measures. Make sure all operators read, un-derstand and follow the contents. This Guideshould be kept in a waterproof bag with the productat all times during operation. If the product owner-ship is transferred, this Guide should be forwardedto the subsequent owners.This Operator’s Guide uses the following signalwords identifying important safety messages.These safety alert signal words mean:ATTENTION! BECOME ALERT!YOUR SAFETY IS INVOLVED!

IMPORTANT: Identifies information that will helpprevent damage to machinery and appears next toinformation that controls correct assembly and op-eration of the product.Although the mere reading of such informationdoes not eliminate the hazard, the understandingand application of the information will promote thecorrect use of your outboard engine.

A responsible, educated boater will fully appreciatethe 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 Squadronand some Red Cross Chapters. For informationabout classes, call toll free 1-800-336-BOAT. Foradditional information about boating safety and reg-ulations call: U.S. Coast Guard Boating Safety Hot-line 1-800-368-5647. Outside North Americaplease contact your Dealer or distributor for detailsabout boating safety.

SAFETY MEASURES — General

SAFETY MEASURES — Operation

DANGERIndicates an imminently hazardous situa-tion which, if not avoided, WILL result indeath or serious injury.

WARNINGIndicates a potentially hazardous situationwhich, if not avoided, CAN result in severeinjury or death.

CAUTIONIndicates a potentially hazardous situationwhich, if not avoided, MAY result in minor ormoderate personal injury or property dam-age. It also may be used to alert againstunsafe practices.

To fully appreciate the pleasures, enjoymentand excitement of boating there are some ba-sic rules that should be observed and fol-lowed by any boater. Some rules may be newto you and others may be common sense orobvious... irrespective, take them seriously!Failure to follow this safety information andsafe boating rules could result in injury to you,your passengers or other water users.

Become completely familiar with the controland operation of your boat and motor beforeembarking on your first trip or taking on a pas-senger(s). If you have not had the opportunityto do so with your Dealer, practice driving ina suitable area and feel the response of eachcontrol. Be familiar with all controls before ap-plying the throttle above idle speed. As theoperator, you are in control and responsiblefor safe operation.

Be sure at least one of your passengersknows how to handle your boat in case of anemergency.

All passengers should know the location ofemergency equipment and how to use it.

All safety equipment and personal flotationdevices must be in good condition and suit-able for your type of boat. Always comply withthe regulations that apply to your boat.

Contact with rotating propeller is likely to re-sult in serious injury or death. Do not allowanyone near a propeller, even when the en-gine is off. Propeller blades can be sharp andcan continue to turn even after the engine isshut off. Always shut off the engine whenboat is near people in the water.

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SAFETY MEASURES — Installation and Maintenance

Outboard Installation

Maintenance

Whenever running the engine, assure thereis proper ventilation to avoid carbon monox-ide (CO), which is odorless, colorless, andtasteless, and can lead to unconsciousness,brain damage, or death if inhaled in sufficientconcentrations. CO accumulation can occurwhile docked, anchored, or underway, and inmany confined areas such as the boat cabin,cockpit, swim platform, and heads. It can beworsened or caused by weather, mooringand operating conditions, and other boats.Avoid exhaust fumes from your engine or oth-er boats, provide proper ventilation, shut offyour engine when not needed, and be awareof the risk of backdrafting and conditions thatcreate CO accumulation. In high concentra-tions, CO can be fatal within minutes. Lowerconcentrations are just as lethal over long pe-riods of time.

Proceed with caution and at very low speedin shallow water. Grounding or abrupt stopsmay result in injury. Also be alert for debrisand objects in the water.

Be familiar with the waters you are operatingin. The gearcase of this outboard extends be-low the water surface and could potentiallycome in contact with underwater obstruc-tions. Contact with underwater obstructionsmay result in loss of control and personal in-jury.

Avoid standing up or shifting weight suddenlyin light weight boats.

Keep your passengers seated in seats. Theboat’s bow, gunwale, transom and seatbacks are not intended for use as seats.

Insist on the use of personal flotation devices,approved by the U.S. Coast Guard, by allpassengers when boating conditions arehazardous, and by children and nonswim-mers at all times.

Respect no wake zones, rights of other waterusers and the environment. As the "skipper"and owner of a boat you are responsible fordamage to other boats caused by the wake ofyour boat. Allow no one to throw refuse over-board.

Know the marine traffic laws and obey them.

Remember, gasoline fumes are flammableand explosive. Always adhere to the fuelingprocedure contained in this Operator’s Guideand those given to you by the fueling station.Always verify fuel level before use and duringthe 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 liquidsin any storage or engine compartments.

Do not operate your boat if you are under theinfluence of drugs or alcohol.

High performance boats have a high power-to-weight ratio. If you are not experienced inthe operation of a high performance boat, donot attempt to operate one at, or near, its topspeed until you have gained that experience.

For more information, see your Evinrude/Johnson Dealer for a copy of Introduction toHigh Performance Boating, P/N 335763.

The outboard must be correctly installed.Failure to correctly install the outboard couldresult in serious injury, death or propertydamage. We strongly recommend that yourDealer install your outboard to ensure properinstallation.

Do not overpower your boat by using an en-gine that exceeds the horsepower indicatedon the boat’s capacity plate. Overpoweringcould result in loss of control. If your boat hasno capacity plate, contact your Dealer or theboat’s manufacturer.

When replacement parts are required, useEvinrude®/Johnson® Genuine Parts or partswith equivalent characteristics, includingtype, strength and material. Using substan-dard parts could result in injury or productmalfunction.

Only perform service procedures which aredetailed in this Operator’s Guide. Attemptingto perform maintenance or repair on your out-board if you are not familiar with the correctservice and safety procedure could causepersonal injury or death. Further informationcan be obtained from your authorizedEvinrude/Johnson Dealer. In many instancesproper tools and training are required for cer-tain service or repair procedures.

Maintain your boat and engine in top condi-tion at all times. Adhere to the Engine Main-tenance and Inspection Schedule.

Operate your boat and outboard prudentlyand have fun. Do not forget that all personsmust assist other boaters in case of emer-gency.

Prevent injury from contact with rotating pro-peller; remove propeller before flushing orbefore performing any maintenance.

General Information - 3

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PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

Bombardier Motor Corporation of America (BMCA)reserves the right to make changes at any time,without notice, to features, specifications and mod-el availability. The right is also reserved to changeany specification or part at any time without incur-ring any obligation to update older models. The in-formation in the Guide is based on the latestspecifications available at the time of publication.Photographs and illustrations used in this Guidemight not depict actual models or equipment butare intended as representative views for referenceonly. The continuing accuracy of this Guide cannotbe guaranteed.Certain features of systems discussed in this Guidemight not be found on all models in all marketing ar-eas.

Owner’s Identification

North America — At the time of purchase, yourDealer will complete your outboard registrationforms. Your portion provides proof of ownershipand date of purchase.

Outside North America — See your Dealer ordistributor 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 stolento Customer and Dealer Support Services, 250 SeaHorse Drive, Waukegan, IL 60085 U.S.A. Give theoutboard’s model and serial numbers and enclosea copy of the police report.

Outside North America — Report the theft to theBombardier Recreational Products distributorwhere the outboard was registered.

Technical Literature

BMCA offers technical literature specifically for youroutboard. A service manual, a parts catalog, or anextra Operator’s Guide can be purchased from yourselling Dealer. For the name and location of thenearest Evinrude/Johnson Dealer in the UnitedStates and Canada log on to www.evinrude.comor www.johnson.com.

Declaration of Conformity

BMCA declares that the outboard to which this Op-erator’s Manual applies conforms to the essentialrequirements outlined in CE Machinery Directive98-37-EC, as amended.

WARNINGWhen replacement parts are required, useEvinrude/Johnson Genuine Parts or partswith equivalent characteristics, includingtype, strength and material. Using substan-dard parts could result in injury or productmalfunction.

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BOMBARDIER MOTOR CORPORATION OF AMERICALIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA

1. SCOPE OF THE LIMITED WARRANTYBombardier Motor Corporation of America* (“BMCA”) warrants its 2005 Johnson® 4-stroke outboard en-gines sold by authorized Johnson dealers in the fifty United States and Canada ("Product") from defectsin material or workmanship for the period and under the conditions described below.

2. WARRANTY COVERAGE PERIODThis limited warranty will be in effect from the date of purchase by the first retail consumer or the date theProduct 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 componentsproviding 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 usedin 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 aboat 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 notextend the life of this limited warranty beyond its original expiration date. All Evinrude/Johnson GenuineParts and accessories installed by an authorized dealer at the time of sale, including but not limited to pro-pellers, bear the standard BMCA parts and accessories one-year limited warranty.

California residents who purchased or warranty-registered a Product in California should refer to BMCA'sCalifornia Emissions Control Warranty Statement.

3. CONDITIONS TO HAVE WARRANTY COVERAGEThis warranty coverage is available only on Johnson 4-stroke outboard engines purchased as new andunused from a dealer authorized to distribute Johnson products in the country in which the sale occurred("Dealer"), and then only after the BMCA specified pre-delivery inspection process has been completedand documented by the purchaser and Dealer. Warranty coverage only becomes available upon properregistration of Product by Dealer or owner.

Only the original purchaser and any subsequent owners who reside in the United States and Canada andhave purchased Product from a U.S. or Canadian Dealer are eligible for warranty registration and warran-ty coverage hereunder. Such limitations are necessary in order to allow BMCA to protect the safety of itsproducts, its consumers, and the general public.

As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintainwarranty coverage. BMCA may require proof of proper maintenance prior to authorizing warranty cover-age.

General Information - 5

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4. WHAT TO DO TO OBTAIN WARRANTY COVERAGEThe 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 appearanceof 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 ofthe repair in order to validate the warranty repair.

All parts replaced under this warranty become the property of BMCA.

5. WHAT BOMBARDIER MOTOR CORPORATION OF AMERICA WILL DOBombardier Motor Corporation of America's obligations under this warranty are limited to, at its sole dis-cretion, repairing or replacing parts of Product found to be defective in material or workmanship, in thereasonable judgment of BMCA. Such repair or replacement of parts will be done without charge for partsand labor, at any authorized Dealer. BMCA's responsibility is limited to making the required repairs or re-placements of parts with new or BMCA-certified re-manufactured parts. No claim of breach of warrantyshall 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 bearresponsibility 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, includingthose levied by governments, states, territories and their respective agencies.

BMCA reserves the right to improve, modify or change Products from time to time without assuming anyobligation to modify Products previously manufactured.

6. EXCLUSIONS - The following are not warranted under any circumstances:• Replacement of parts due to normal wear and tear;• Routine maintenance parts and services including but not limited to: maintenance requirements, engine

and lower unit oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zincanodes, 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, failureto follow the procedures and recommendations in the Operator's Guide;

• Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or useof parts or accessories not manufactured or approved by BMCA, which in its reasonable judgment, areeither incompatible with Product or adversely affect its operation, performance, or durability, or resultingfrom repairs done by a person that is not an authorized Dealer;

• Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation ofthe Product in a manner inconsistent with the recommended operation described in the Operator'sGuide;

• Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalismor any act of God;

• Operation without proper fuel, oil or lubrication or with fuels, oils or lubricants which are not suitable foruse with the Product (see the Operator's Guide);

• Damage resulting from rust or corrosion;• Damage caused from cooling system blockage by foreign material;• Damage resulting from sand or debris in the water pump;• Cosmetic or paint changes due to exposure to the elements.

This warranty will be voided in its entirety and rendered null and void where:• Product has been altered or modified in such a way so as to adversely affect its operation, performance

or durability, or change its intended use, horsepower or emission levels; or• Product is or has been used for racing at any point, even by a prior owner.

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7. LIMITATIONS OF LIABILITYALL 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 KINDARE 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 aboat and reinstallation, mechanic's travel time, in-and-out of water charges, slip or dock fees, trailering ortowing, storage, telephone, cell phone, fax or telegram charges, rental of a like or replacement Product orboat 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 YOUSPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROMSTATE TO STATE, OR PROVINCE TO PROVINCE.

No distributor, Dealer or any other person is authorized to make any affirmation, representation or war-ranty regarding Product other than those contained in this limited warranty and, if made, shall not be en-forceable against BMCA. BMCA reserves the right to modify this warranty at any time, being understoodthat such modification will not alter the warranty conditions applicable to the Products sold while this war-ranty is in effect.

8. TRANSFERIf the ownership of Product is transferred during the warranty coverage period, this warranty shall also betransferred and be valid for the remaining coverage period provided that the former or new owner promptlycontacts BMCA or Dealer and gives the name and address of the new owner.

9. CONSUMER ASSISTANCE• In the event of a controversy or dispute in connection with this BMCA limited warranty, BMCA recom-

mends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer'sservice manager or owner;

• If further assistance is required, please contact the Bombardier Motor Corporation of America CustomerSupport Services, 250 Sea Horse Drive, Waukegan, IL, 60085, 1-847-689-7090.

Revision March 2004* Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc.

General Information - 7

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BOMBARDIER MOTOR CORPORATION OF AMERICALIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES

SOLD OUTSIDE THE UNITED STATES AND CANADA

For a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distrib-utor/dealer authorized to distribute Johnson 4-Stroke products in the country in which the sale occurs.

If further assistance is required, please contact Bombardier Motor Corporation of America Customer Sup-port Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BMCA where the Productwas registered for warranty.

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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, describesthe meaning of the star rating system.

The Star Label means Cleaner Marine Engines

The Symbol for Cleaner Marine Engines:Cleaner Air and Water

For a healthier lifestyle and environment. Better Fuel Economy

Burns up to 30 to 40 percent less gas and oil than conventionalcarbureted two-stroke engines, saving money and resources.

Longer Emission WarrantyProtects consumer for worry free operation.

One Star – Low EmissionThe one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir 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 EmissionThe two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir 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 EmissionThe 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 2003exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star– Low Emission engines.

Four Stars – Super Ultra Low EmissionThe four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marineengine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may alsocomply with these standards. Engines meeting these standards have 90% lower emissions than One Star– Low Emission engines.For more information: Cleaner Watercraft – Get the Facts

1-800-END-SMOGwww.arb.ca.gov

YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATIONThe California Air Resources Board and Bombardier Motor Corporation of America (“BMCA”) are pleasedto explain the emission control system warranty on your Johnson 4-stroke outboard. In California, newoutboard engines must be designed, built, and equipped to meet the State's stringent anti-smog stan-dards. BMCA must warrant the emission control system on your outboard for the periods of time listedbelow 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, BMCA will repair your outboard at no cost to you including diagno-sis, parts, and labor provided that such work is performed by an authorized BMCA dealer.

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Manufacturer's Limited Warranty CoverageThis emission limited warranty covers Johnson 4-stroke outboards certified and produced by BMCA forsale in California, that are originally sold in California to a California resident, or subsequently warranty-registered to a California resident. The BMCA U.S. and Canada limited warranty conditions for Johnson4-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 purchaseby the first retail consumer or the date the product is first put to use, whichever occurs first, for a periodof: 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 theappropriate hour meters or their equivalent. If any emission-related part on your engine is defective underwarranty, the part will be repaired or replaced by BMCA.Parts covered are:

Component Carbureted SPFI Thermostat X XElectrical System Engine/Ignition Control Module X X Spark Plugs, Boots, and/or Wires X X Ignition Coils X X Wiring Harness X XExhaust System Engine Holder X X Oil Pan X X Exhaust Housing X X Exhaust Valves X XFuel System Fuel Pump(s) X X Fuel Injectors X Vapor Separator X Carburetor and Internal Parts X Accelerator Pump X Choke System X Crankcase Ventilation System Components X X Fuel Lines, Fittings, Clamps X XAir Induction System Timing Chain/Belt and Tensioner X X Camshaft and Followers X X Intake Valves X X Electronic Dash Pot System X Throttle Body Assembly X Idle Air Control X Closed Throttle Position Switch X Throttle Linkage X X Intake Manifold X XSensors Air Temperature Sensor X Cam Position Sensor X Crankshaft Position Sensor X X Throttle Position Sensor X Exhaust Temp Sensor X Intake Manifold Pressure Sensor X Cylinder Temperature Sensor X XGaskets All Emission Component Gaskets X X

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The emission warranty covers damage to other engine components that is caused by the failure of a war-ranted part.The BMCA Operator's Guide provided contains written instructions for the proper maintenance and useof your outboard. All emission warranty parts are warranted by BMCA for the entire warranty period of theoutboard, 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 byBMCA for the period of time before the first scheduled replacement date for that part. Emission warrantyparts that are scheduled for regular inspection but not regular replacement are warranted by BMCA forthe entire warranty period of the outboard. Any emission warranty part repaired or replaced under theterms of this warranty statement is warranted by BMCA for the remainder of the warranty period of theoriginal part. All parts replaced under this limited warranty become the property of BMCA.Maintenance receipts and records should be transferred to each subsequent owner of the outboard.Owner's Warranty ResponsibilitiesAs the outboard owner, you are responsible for the performance of the required maintenance listed in yourOperator's Guide. BMCA recommends that you retain all receipts covering maintenance on your out-board, but BMCA cannot deny warranty solely for the lack of receipts or your failure to ensure the perfor-mance of all scheduled maintenance.As the outboard owner, you should however be aware that BMCA may deny you warranty coverage if youroutboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.You are responsible for presenting your outboard to an authorized BMCA dealer as soon as a problemexists. 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 thenearest authorized BMCA dealer, contact Bombardier Motor Corporation of America Customer SupportServices, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.johnson.com.

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FEATURES

Item Description Item Description

1 Water Pump Indicator 7 Lubricant Level Plug

2 Antiventilation Plate 8 Transom Bracket

3 Trim Tab 9 Crankcase Oil Drain Plug

4 Propeller (1) 10 Steering Connector

5 Lubricant Drain/Fill Plug 11 Installation Hardware

6 Water Intake 12 SystemCheck Gauge (1)

(1) not supplied with outboard

1

2

3

5

67

8

9

000256

4

10

11

12

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Item Description Item Description

13 Tool Kit 17 Flushing Port

14 Crankcase Oil Drain Screw Gaskets 18 Water Intake

15 Remote Control (1)

(1) not supplied with outboard

19 Anticorrosion Anodes

16 Motor Cover 20 Power Trim and Tilt Switch

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000257

13 14

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General Information - 13

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ENGINE SPECIFICATIONS

90, 115 Models

Displacement 119.0 cu. in. (1950 cm3)

Engine Type Four-Cycle, In-line, 4 CylinderElectronic Fuel Injection

Full Throttle Operating Range 90 - 4500 to 5500 RPM115 - 5000 to 6000 RPM

Power (1)

(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.

90 - 90 HP (67.1 kw) @ 5000 RPM115 - 115 HP (85.8 kw) @ 5500 RPM

Idle RPM in Gear (2)

(2) Emission Control Information.

625 ± 25

Ignition Timing – Idle (2)

W.O.T.Not AdjustableNot Adjustable

Exhaust Emission Control System:per SAE J1930 (2)

SFI

Fuel Requirements (2) 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil

Crankcase – OilCapacity

Evinrude/Johnson Ultra™ 4-Stroke synthetic blend oil5.8 qts. (5.5 liters)

Warning Signals Engine Overheat and Low Oil Pressure

Ignition Features S.L.O.W.™ (Speed Limiting Overheat Warning)

Starting Remote electric

Battery, Minimum (3)

(3) Not supplied in all marketing areas.

12-Volt, 500 CCA (620 MCA) with 160 minutes reserve capacityOR 100 ampere-hour

Spark Plug (2)

TorqueRefer to ECI Label18 to 21 ft. lbs. (24 to 28 N·m)

Fuse Refer to Fuses

Fuel Line Filter P/N 5033704

Alternator 17-Amp, Fully Regulated

Gearcase – Lubricant Capacity

Evinrude/Johnson Ultra-HPF™ gearcase lubricant35.5 fl. oz. (1050 ml)

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

Propeller (3) 90 - See your Dealer115 - See your Dealer

Weight L - 416 lbs. (189 kg)X - 427 lbs. (194 kg)

Sound at Driver’s Ear(LpA) ICOMIA 39.94

90 - 82.0 dB(A)115 - 84.2 dB(A)

Transom Height L - 19 1/2 to 20 in. (49.5 to 50.8 cm)X - 24 1/2 to 25 in. (62.2 to 63.5 cm)

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ENGINE SPECIFICATIONS

140 Models

Displacement 124.7 cu. in. (2044 cm3)

Engine Type Four-Cycle, In-line, 4 CylinderElectronic Fuel Injection

Full Throttle Operating Range 5600 to 6200 RPM

Power (1)

(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.

140 HP (103.0 kw) @ 5900 RPM

Idle RPM in Gear (2)

(2) Emission Control Information.

700 ± 25

Ignition Timing – Idle (2)

W.O.T.Not AdjustableNot Adjustable

Exhaust Emission Control System:per SAE J1930 (2)

SFI

Fuel Requirements (2) 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil

Crankcase – OilCapacity

Evinrude/Johnson Ultra 4-Stroke Synthetic Blend Oil5.8 qts. (5.5 liters)

Warning Signals Engine Overheat and Low Oil Pressure

Ignition Features S.L.O.W.™ (Speed Limiting Overheat Warning)

Starting Remote electric

Battery, Minimum (3)

(3) Not supplied in all marketing areas.

12-Volt, 512 CCA (620 MCA) with 160 minutes reserve capacityOR 100 ampere-hour

Spark Plug (2)

TorqueRefer to ECI Label18 to 21 ft. lbs. (24 to 28 N·m)

Fuse Refer to Fuses

Fuel Line Filter P/N 5033704

Alternator 17-Amp, Fully Regulated

Gearcase – Lubricant Capacity

Evinrude/Johnson Ultra-HPF gearcase lubricant35.5 fl. oz. (1050 ml)

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

Propeller (3) See your Dealer

Weight L - 410 lbs. (186 kg)X - 421 lbs. (191 kg)

Sound at Driver’s Ear(LpA) ICOMIA 39.94

86.6 dB(A)

Transom Height L - 19 1/2 to 20 in. (49.5 to 50.8 cm)X - 24 1/2 to 25 in. (62.2 to 63.5 cm)

General Information - 15

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REMOTE CONTROL

IMPORTANT: When selecting the remote controlsystem for your boat, specify Evinrude/Johnsoncomponents. Evinrude/Johnson offers remote con-trols, cables and wiring kits designed specifically foryour Evinrude/Johnson outboards. Evinrude/Johnson controls deliver the cable stroke your out-board needs for positive shift and throttle control,and they incorporate such safety and conveniencefeatures as:Start-in-gear preventionPlug-in compatibility with Evinrude/Johnson modu-lar wiring system

Evinrude/Johnson concealed side mount control1. Handle – shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle button5. Throttle friction control

Evinrude/Johnson binnacle mount control1. Handle – shift and throttle2. Trim/tilt switch (where equipped)3. Fast idle button4. Throttle friction control5. Emergency stop clip and lanyard

Evinrude/Johnson side mount control1. Handle – shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle lever5. Emergency stop clip and lanyard6. Throttle friction control

WARNINGIf you choose a non-Evinrude/Johnsonremote control, be sure it has a start-in-gearprevention feature. This feature can preventinjuries resulting from unexpected boatmovement when the engine starts.

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Emergency Stop/Key SwitchA combination emergency stop switch and keyswitch is a feature of Evinrude/Johnson prewiredremote controls and all Evinrude/Johnson controlwiring kits. Use of the emergency stop feature ishighly 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 tearaway instead of activating the stop switch. Discon-necting the clip and lanyard will stop the engine andprevent the boat from becoming a runaway if thedriver moves beyond the range of the lanyard. If thelanyard is too long, it can be shortened by knottingor looping it. DO NOT cut and retie the lanyard. Inan emergency situation, the engine can be startedwithout the clip in place. Follow the normal startingprocedure. Reinstall a clip as soon as possible.

1. Clip2. Emergency stop / key switch3. Lanyard

WARNINGAvoid knocking or pulling the clip off thestop switch during normal boating. Avoidbumping the key if operating without theclip on the switch. The resulting unexpectedloss of forward motion can throw occupantsforward, causing injury.

Your emergency stop switch can be effec-tive only when in good working condition.At each outing, inspect clip and lanyard forcuts, breaks, or wear. Replace worn or dam-aged parts.

Keep the lanyard free from obstructions andentanglements.

At each outing, test the system’s operation.With the engine running, remove the clipfrom the switch by pulling the lanyard. If theengine does not stop running, see yourDealer.

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ENGINE MONITORING

IMPORTANT: Your outboard must be equippedwith the SystemCheck™ (or equivalent) enginemonitor. Operating your outboard without the Sys-temCheck (or equivalent) engine monitor will voidyour warranty for failures related to the functionsmonitored on your engine.When you turn the key switch ON, the System-Check engine monitor horn performs a self-test bysounding a 1/2-second beep. The gauge self-testsby turning the warning lights on, then off in se-quence. During engine start-up, pause with the keyswitch in the ON position to observe the horn andgauge perform the self-test. If the self-test does nothappen as stated, see your Dealer.The SystemCheck engine monitor alerts the opera-tor with a 10-second beep of the horn and a warninglight on the gauge when certain engine problemsoccur. The appropriate warning light will stay onuntil the key switch is turned OFF.If the engine management module (EMM) sensesthat the problem could cause permanent enginedamage, it will also limit engine speed to 3000RPM. This additional protection feature is referredto as S.L.O.W.™ If the engine was running fasterthan 3000 RPM when the S.L.O.W. system activat-ed, it will shake noticeably.

1. SystemCheck Gauge2. SystemCheck Gauge with Tachometer

"NO OIL"

The engine’s oil pressure is too low to continue nor-mal operation. Serious engine damage can occurquickly. The EMM will limit the engine speed to3000 RPM.Causes of low oil pressure can include:• Insufficient oil in the crankcase.• Air in the system causing oil to foam.• Malfunction of oil delivery components.• Blockage of oil system components.

To RESET the S.L.O.W. protection system – Oilpressure must be restored and engine slowed to3000 RPM.Return to harbor if you cannot restore adequate oilpressure. For more information about evaluatinglow oil pressure, refer to Low Oil Pressure Warn-ing.

"WATER TEMP" or HOT

The engine is overheating. Serious engine damagecan occur quickly.If the engine is overheating, it will also activateS.L.O.W. and limit engine speed to 3000 RPM.

IMPORTANT: Refer immediately to Engine Over-heating.

CAUTIONIn the S.L.O.W. mode, the engine speed islimited. Under certain conditions, theengine’s limited speed may reduce maneu-verability of your boat.

If the S.L.O.W. mode is activated and youare unable to correct the problem, seekassistance and/or return to safe harbor.Serious engine damage, engine shutoff,and/or reduced maneuverability may beimminent.

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18 - Engine Monitoring

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FUEL AND OIL

FUEL

Your outboard is certified to operate on unleadedautomotive gasoline with an octane rating equal toor higher than that specified in Minimum Octanechart. When using gasoline that contains MTBE oralcohol, follow these guidelines:Using unleaded gasoline that contains methyl ter-tiary butyl ether (MTBE) is acceptable ONLY if theMTBE content does not exceed 15% by volume.Using alcohol-extended fuels is acceptable ONLY ifthe alcohol content does not exceed:10% ethanol by volume; or5% methanol with 5% cosolvents by volume

Minimum Octane

Your outboard has been designed to operate usingthe 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 tothe boat’s owner manual.Alcohol attracts and holds moisture that can causecorrosion of metallic parts in the fuel system.Alcohol blended fuel can cause engine perfor-mance problems.

IMPORTANT: Always use fresh gasoline. Gasolinewill oxidize and weather; the result is loss of octane,volatile compounds, and the production of gum andvarnish deposits which can damage the outboard.

WARNINGGasoline is extremely flammable and highlyexplosive under certain conditions. Followthe instructions in this section explicitly.Improper handling of fuel could result inproperty damage, serious injury, or death.

Always turn off the engine before fueling.

Never permit anyone other than an adult torefill the fuel tank.

Do not fill the fuel tank all the way to the topor fuel may overflow when it expands due toheating by the sun.

Remove portable fuel tanks from the boatbefore fueling.

Always wipe off any fuel spillage.

Do not smoke, or allow open flames orsparks, or use electrical devices such ascellular phones in the vicinity of a fuel leakor while fueling.

Always work in a well-ventilated area.

Inside the U.S. 87 (R+M)/2 AKI

Outside the U.S. 90 RON

WARNINGLeaking fuel is a fire and explosion hazard.All parts in the fuel system should beinspected frequently and replaced if signsof deterioration or leakage are found.Inspect the fuel system each time yourefuel, each time you remove the enginecover and annually.

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OIL

Your 4-stroke engine requires oil in the crankcase.Evinrude/Johnson Ultra 4-Stroke syntheticblend oil is recommended for this outboard en-gine. It allows for extended oil change intervals andis best for high load applications. Evinrude/JohnsonUltra 4-Stroke synthetic blend oil delivers ultra vis-cosity stability, sludge protection, friction reducingproperties, and superior corrosion protection.If Evinrude/Johnson Ultra 4-Stroke synthetic blendoil is unavailable, you may use Evinrude/Johnson4-Stroke outboard oil. This oil provides excellentwear and corrosion resistance under normal oper-ating conditions. For your engine’s oil capacity, re-fer 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 byBMCA for your outboard. Use of other fuel additivescan result in poor performance or engine damage.Evinrude/Johnson 2+4 fuel conditioner will helpprevent gum and varnish deposits from forming infuel system components and will remove moisturefrom the fuel system. It can be used continuouslyand should be used during any period when yourengine is not being operated on a regular basis. Itsuse will reduce spark plug fouling, fuel system icing,and fuel system component deterioration.

FUEL SYSTEM

IMPORTANT: Fuel distribution hoses in the boatmust deliver fuel at the rate of flow needed by theengine. Minimum inside diameter of fuel hosesmust be 5/16 in. (8 mm).Fuel systems with built-in tanks, particularly thosethat include antisiphon valves and filter/primerunits, may have restrictions that will not allow theengine fuel pump to deliver sufficient fuel under allconditions. This can result in a loss of performanceand possible engine damage. If a performanceproblem exists, see your Dealer.To avoid difficulty when restarting, never run theengine with the fuel hose disconnected, or run theengine out of fuel.

WARNINGIf your motor is equipped with a quick-dis-connect fuel hose, disconnect the fuel hosefrom the motor and from the fuel tank whenthe motor is not being used for a period oftime. Disconnecting the hose will avert fuelleaks in the hose or at the engine.

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BREAK-IN (10 HOURS)

IMPORTANT: 4-Stroke outboards are shippedwithout oil in the crankcase. You must add oil tothe crankcase before starting the engine for thefirst time. It is recommended you add Evinrude/Johnson 4-Stroke outboard oil. Refer to Changingthe Oil for acceptable substitute lubricants.Follow this procedure to protect your new outboardduring its initial hours of operation. Careful break-inallows internal engine components to “seat” proper-ly, resulting in maximum engine performance.Failure to carefully follow the break-in procedurescan result in engine damage.High speed operation without sufficient enginewarm-up can result in engine damage.Perform the 10-Hour break-in procedure with theboat and engine in the water, using an appropriatepropeller.DO NOT perform break-in using a flushing device.DO NOT start-up or run the engine out of water.DO NOT leave a running engine unattended.

IMPORTANT: Before the start-up of your new en-gine:• Read Engine Starting, Engine Stopping and

Speed Control.• Check the crankcase oil level. Refer to Crank-

case Oil and Filter.• Perform prelaunch checks of all equipment.

Launch the boat and start the engine according tothe 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 thecause, 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 throttlesetting longer than 15 minutes.

• Check the crankcase oil level often. Add oil ifneeded.

First 10 minutes of operation — Operateengine in gear at idle only.

Balance of First 2 hours of operation — Oper-ate in gear below 3000 RPM or 1/2 throttle only.With easy planing boats, use full throttle to quicklyaccelerate boat onto plane. Immediately reducethrottle 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 ingear at various speeds up to 4000 RPM or 3/4 throt-tle only.

Balance of first 10 hours of operation — Runthe engine in gear at various engine speeds includ-ing full throttle, but remain at full throttle no longerthan 5 minutes.Change the engine speed every 15 minutes.DO NOT exceed recommended maximum engineRPM. Refer to Engine Specifications.

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ENGINE STARTING

BEFORE START-UP

Verify crankcase oil level before start-up. Refer toCrankcase Oil and Filter.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 occurquickly. Refer to Engine Overheating or Flushing.Be sure the engine is in RUN position. Refer toPower Trim and Tilt or Tilting.

Connect the fuel hose to the fuel connector.

1. Fuel hose to fuel connector

If the fuel tank has an operable vent, open it.Squeeze the fuel primer bulb, outlet end up, untilfirm.

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 tearaway instead of activating the stop switch.

1. Clip2. Emergency stop / key switch3. Lanyard

DANGERDO NOT run the engine indoors or withoutadequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

WARNINGThe engine cover is a machinery guard. DONOT operate your outboard with the coveroff unless you are performing maintenance,and then be careful to keep hands, hair, andclothing clear of all moving parts. Contactwith moving parts could cause injury.

WARNINGContact with a rotating propeller is likely toresult in serious injury or death. Assure theengine and prop area is clear of people andobjects before starting engine or operatingboat. Do not allow anyone near a propeller,even when the engine is off. Blades can besharp and the propeller can continue to turneven after the engine is off. Always shut offthe engine when near people in the water.

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22 - Engine Starting

Page 25: Johnson 140

IMPORTANT: The engine will start and run withoutthe clip connected to the key switch. However, westrongly recommend that the operator use the clipand lanyard anytime the engine is running. Refer toEmergency Stop/Key Switch.Move the remote control handle to NEUTRAL. Re-fer to Shifting and Speed Control.

1. NEUTRAL

Start-up

Turn the key switch fully clockwise to the STARTposition. Crank the engine no longer than 10 sec-onds.

1. START

IMPORTANT: The starter motor can be damaged ifoperated 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 EngineMonitoring. If the warning system fails to self-testduring start-up, see your Dealer.If your outboard does not react normally to thisstarting procedure or if it fails to start, refer to Trou-ble Check Chart.

After Engine StartsDO NOT turn the key switch to START while the en-gine is running. Damage to the starter system couldresult.Allow the engine to idle in NEUTRAL for about 5minutes to warm up before shifting.

IMPORTANT: To avoid engine damage after start-up do not exceed 2000 RPM in NEUTRAL. Do notexceed 1500 RPM in NEUTRAL for extended peri-ods of time.Check the water pump indicator. A steady stream ofwater indicates the water pump is working. If asteady stream of water from the water pump indica-tor is not visible, stop the engine. Refer to EngineOverheating.

ENGINE STOPPING

Move control handle to NEUTRAL.Turn key switch counterclockwise to OFF. Removethe key when the boat will be unattended.To avoid difficulty when restarting, never stop theengine by running it with the fuel hose disconnectedor otherwise running it out of fuel.The engine’s EMM draws a small amount of currentat all times. When you are not planning to run yourengine within the next 30 days:• If your boat is equipped with a battery switch, turn

it OFF.• If you have no battery switch, remove the 60-amp

fuse. Refer to Fuses.

IMPORTANT: With the 60-amp fuse removed, theengine will not crank or start. Place a note on yourignition key to install the fuse before your next out-ing.

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SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function of allcontrol and engine systems before leaving thedock. DO NOT shift the engine into FORWARD orREVERSE while it is shut OFF. If the following di-rections are not suitable for your boat’s control, seeyour Dealer before proceeding.

ShiftingWith engine running and control handle in NEU-TRAL:

Side Mount and Concealed Side Mount Control

Unlock the control handle (lift the neutral lock tab bysqueezing the hand grip). Briskly and decisively,move the control handle fore or aft — until it engag-es the gear detent.

1. Side mount NEUTRAL lock tab hand grip2. Concealed side mount NEUTRAL lock tab

hand grip

Binnacle Mount Control

Briskly and decisively, move the control handle foreor aft — until it engages the gear detent.

IMPORTANT: When shifting from FORWARD toREVERSE or from REVERSE to FORWARD,pause at NEUTRAL until the engine is at idle speedand the boat has slowed.

Speed ControlAfter gear engagement, move the control handleslowly in the same direction to increase speed.

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Fast Idle in NEUTRAL

Concealed Side Mount and Binnacle Mount Con-trols

IMPORTANT: Avoid excessive engine RPM inNEUTRAL — adjust the throttle so the engine doesnot overspeed.With the control handle in NEUTRAL, push the fastidle button while using the other hand to move thecontrol handle forward, past the forward gear de-tent and into the throttle range. If equipped with aneutral lock tab, squeeze it to begin handle travel.

1. Fast idle button

When ready to shift, move the control handle backto NEUTRAL. Engine speed will reduce and theshift function will automatically engage for move-ment into FORWARD or REVERSE.On models with QuikStart electronic starting or fuelinjection, use the Fast Idle in NEUTRAL featureonly to clear a flooded condition. Refer to TroubleCheck Chart.

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 tothe economy throttle range. You will save fuel with-out a noticeable loss of speed.

1. Concealed side mount control2. Binnacle mount control

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OPERATION

POWER TRIM AND TILT

The trim system features a trim range of 30°:You can pivot the engine to any position within thisrange while underway and at any boat speed.The power trim is normally used to improve accel-eration, speed, and ride quality and to adjust forchanging water conditions.

The tilt system will tilt your engine an additional 45°:While positioned within the tilt range, DO NOT runthe engine faster than idle speed. If idling a tiltedengine, keep its water intakes submerged at alltimes.

The power tilt is often used to tilt the engine forclearance when beaching, mooring, or launching.

1. Trim range 2. Tilt range

Trim GaugeThe trim gauge indicates the bow position that isachieved by the trim angle of your motor.

DANGERDO NOT run the engine indoors or withoutadequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

WARNINGContact with a rotating propeller is likely toresult in serious injury or death. Assure theengine and prop area is clear of people andobjects before starting engine or operatingboat. Do not allow anyone near a propeller,even when the engine is off. Blades can besharp and the propeller can continue to turneven after the engine is off. Always shut offthe engine when near people in the water.

WARNINGAny malfunction of the power trim and tiltunit could result in loss of shock absorberprotection if an underwater obstruction ishit. Malfunction can also result in loss ofreverse thrust capability.

WARNINGDisconnect the fuel line whenever you leavethe motor tilted up for a long period of time,or fuel may leak out.

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Manual Release

If needed, the outboard will tilt up or down manually:Turn the manual release screw counterclockwise,slowly, about 2 turns.Reposition the engine.Tighten the manual release screw to hold the en-gine in its new position.

1. Manual release screw

TiltingTo operate the power tilt, push and hold the trim/tiltswitch in the bow-up or bow-down position. The en-gine will tilt up or down until the switch is releasedor the engine reaches the end of its travel.

1. Bow up2. Bow down

TrimmingTo operate the power trim, push and hold the trim/tilt switch in the desired bow direction, either bow-up or bow-down. The engine will move until theswitch is released or the engine reaches its maxi-mum position.The boat will be properly trimmed when the trim an-gle provides a bow position that results in the bestboat performance for your operating conditions.You must use a speedometer and tachometer todetermine boat and engine performance at differenttrim positions. To help maintain steering stabilityand good performance, always maintain the propertrim angle, which varies depending on the combina-tion of boat, motor, propeller, and operating condi-tions.To familiarize yourself with power trim, make testruns with the boat’s bow at various positions. Notethe time it takes for the boat to plane, the tachome-ter and speedometer readings, and the ride and ac-tion of the boat.

WARNINGKeep everyone clear of a tilted engine whenbacking out the manual release screw. Theengine could drop suddenly and forcibly. Besure to tighten the manual release screwafter manually repositioning the engine.Tightening the screw also reactivates theengine’s shock absorber protection andreverse thrust capability.

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Bow-UpBOW-UP position will give the best fuel economyand highest top speed.

Operating Conditions:

In the bow-up position, your boat may tend to pull tothe left. If this condition exists, correct it by applyinga clockwise force with the steering wheel to keep ona straight path. The trim tab can also be adjusted tocompensate for steering wheel torque, but adjustthe trim tab only if bow-up is commonly used. Referto Trim Tab.When the motor is trimmed to full bow-up position,the boat’s bow will tend to rise above the water.Excessive bow-up trim may cause propeller ventila-tion, resulting in propeller slippage.

Bow-DownBOW-DOWN position will give the best accelera-tion onto plane and the best towing power for skiing.The bow-down position is normally used for accel-erating from a standing start or from idle speed.

Operating Conditions:

In the bow-down position, your boat may tend topull to the right. If this condition exists, correct it byapplying a counterclockwise force with the steeringwheel to keep on a straight path. The trim tab canalso be adjusted to compensate for this steeringwheel torque, but adjust the trim tab only if bow-down is commonly used. Refer to Trim Tab.When the motor is trimmed to full bow-down posi-tion, the boat’s bow will tend to go deeper into thewater (plow).

IMPORTANT: Some boats plow, or are difficult toplane, when operated in the trim’s lowest position.If your boat handles unsuitably when trimmed fullybow-down, set the angle adjusting rod or trim limiterrod to limit the travel of the power trim. If your motoris not equipped with this rod, purchase one fromyour Dealer.

WARNINGWhen operating in rough water or crossinga wake, excessive bow-up trim may result inthe boat’s bow suddenly rising skyward,possibly ejecting occupants.

WARNINGSome boat/motor/propeller combinationsmay encounter boat instability and/or highsteering torque when operated at highspeed at or near the motor’s trim range lim-its (full bow-up or bow-down). Boat stabilityand steering torque can also vary due tochanging water conditions. If any adverseconditions occur, reduce throttle and/oradjust trim angle to maintain control. If youexperience boat instability and/or highsteering torque, see your Dealer to correctthese conditions.

WARNINGIf the bow of the boat plows the water athigh speeds, the boat may bow steer or spinsuddenly, possibly ejecting occupants.

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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 installingpropeller.

IMPORTANT: The correct propeller for your boat,under normal load conditions, will allow the engineto run near the midpoint of the RPM operatingrange at full throttle. Refer to Engine Specifica-tions.Right-hand propellers are considered standard ro-tation propellers. When propelling a boat forward,the propeller rotates in a right-hand (clockwise) di-rection as viewed from the rear.Left-hand propellers are considered counter-rota-tion propellers. When propelling a boat forward, thepropeller rotates in a left-hand (counterclockwise)direction as viewed from the rear.

1. Right-hand (clockwise)2. Left-hand (counterclockwise)

MOORING

You may moor your boat with the motor’s gearcaseout of the water by using its tilt feature. Dependingon the model, refer to Tilt Support or Power Trimand Tilt.

FLUSHING

See your Dealer for a flushing device designed to fityour engine. Follow manufacturer’s instructions forinstalling and using it.

Outboard — Running

1) Place the engine in vertical position in a well-ventilated area with good drainage.

2) Install flushing device and garden hose.

WARNINGIf you have a dual engine installation thatincludes a counter-rotating engine and youremove the propellers, always check to besure they are installed on the correctengines before aggressively operating yourboat. Shift each motor individually intoFORWARD or REVERSE, at idle speed only.If the boat moves opposite the directionindicated by the remote control handle, thewrong propeller has been installed on themotor being checked. Install the correctpropeller and confirm your installationusing the above method before any attemptis made to operate the boat.

DANGERDO NOT run the engine indoors or withoutadequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

WARNINGPrevent injury from contact with rotatingpropeller; remove the propeller beforeflushing.

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3) Place the remote control lever in NEUTRALwith the propeller removed.

4) Start the water — keep pressure between 20to 40 psi (140 to 300 kPa).

5) Start the engine — run it at idle only andflush it for at least five minutes. Check thewater pump indicator. A steady stream of wa-ter must flow. If it does not, shut OFF the en-gine and investigate. Refer to EngineOverheating.

6) Shut OFF the engine and remove the flusher.7) Leave the outboard in vertical position long

enough to completely drain the powerhead.

Outboard — Not Running1) Place the engine in a tilted or vertical posi-

tion.2) Remove the plug from the flushing port.3) Install flushing device (if needed) and garden

hose.

1. Flushing port2. Garden hose

4) If needed, use a hose connector matched tothe flushing port thread. The flushing portthread is 0.75 – 11.5 NHR (ANSI). A suitableconnector is commercially available at mosthardware outlets.

1. Flushing port thread2. Garden hose

5) Start the water and flush the engine for atleast five minutes — keep pressure between20 and 40 psi (140 and 300 kPa).

6) Remove the flusher (if used). Install the plug.7) Lower the outboard to vertical position long

enough to completely drain the powerhead.1

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ENGINE OVERHEATING

IMPORTANT: Do not run your engine — even for abrief start-up — without supplying water to it. Referto Flushing.

While boating, the engine’s water intakes must staycompletely submerged and unobstructed. Observeproper transom height and trim angle.While the engine is running, the engine’s waterpump indicator must discharge a steady stream ofwater. Check the indicator often, especially whenoperating in weeds, muddy and debris-laden water,and at extreme trim angles.

1. Water intake screens2. Water pump indicator

If the engine overheats, its SystemCheck enginemonitor will sound the warning horn and turn on the"WATER TEMP" or HOT light. Also, the EMM willimmediately limit the engine’s speed to 3000 RPM.This additional protective feature is referred to asS.L.O.W. If the engine was running faster than3000 RPM when the S.L.O.W. system activated, itwill shake noticeably.IF the S.L.O.W. protection system activates and thestream 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 of any blockage;Clean the water pump indicator of any blockage;Lower the motor; andRestart the engine and run at idle.

IF cleaning the screens and indicator does not re-store the water pump indicator’s steady discharge,SHUT OFF the engine and do not attempt to oper-ate it. See your Dealer.IF cleaning the screens and indicator does restorethe water pump indicator’s steady discharge, youmight have to run for two minutes in NEUTRAL toallow the engine to cool and the light to go off.If the warning light stays on after two minutes,STOP the engine and see your Dealer.

IMPORTANT: You must restore cooling to the en-gine to avoid serious engine damage.After any overheat, have your Dealer:Torque the exhaust manifold bolts and zinc anodecover and the cylinder head screws.Inspect the water pump for excessive wear or dam-age.Inspect the water pipe and its O-ring.Inspect the condition and sealing of the exhaustmanifold gasket.Inspect the thermostats.Inspect the engine for leaks.Inspect water pressure valve.Check engine oil level.

Low Oil Pressure WarningShould the oil pressure drop to a dangerously lowlevel, the SystemCheck engine monitor will soundthe horn and turn on the “NO OIL” light. Also, theEMM will immediately limit the engine speed to3000 RPM. This additional protective feature is re-ferred to as S.L.O.W. If the engine was running fast-er than 3000 RPM when the S.L.O.W. systemactivated, it will shake noticeable.In case of low oil pressure:Shut OFF engine.If tilted, place the engine in vertical position.Check the oil level on the dipstick and add oil, ifneeded. Refer to Crankcase Oil and Filter andEngine Specifications.Examine the oil fill cap and drain screw for evidenceof leakage. Make sure each is tight.If dipstick shows that the oil level is okay, leave theengine upright and shut off for 10 minutes, thenstart it. If the engine still limits itself to about 3000RPM, see your Dealer.

IMPORTANT: DO NOT attempt to run your engineif it repeatedly loses oil pressure. See your Dealer.

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TRAILERING

Trailer your boat with the motor in a vertical posi-tion. If your trailer does not provide adequate roadclearance, the motor can be trailered by using anaccessory 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 andboat’s transom.

TILT SUPPORT

IMPORTANT: DO NOT use the tilt support leverwhile trailering. Refer to Trailering.

Engage the tilt support lever if you intend to leavethe motor tilted for a period of time:• Tilt the motor UP using the trailering tilt switch.• Flip the tilt support lever down.

1. Tilt support lever

• Lower the motor until the tilt support lever restssolidly on the stern brackets.

Disengage the tilt support lever:• Tilt the motor UP.• Flip the tilt support level up.• Lower the motor to operating position.

WARNINGKeep everyone clear of stern area whenraising or lowering the outboard. Personalinjury or death can result from contact withmoving parts of the outboard.

WARNINGAlways use the power tilt to lift and supportthe motor BEFORE you disengage the tiltsupport lever. If oil pressure is lost whileusing the tilt support lever, the motor candrop suddenly when the support is disen-gaged. If the power tilt will not lift the motor,do not attempt to force the tilt lever from itsposition on the stern brackets. See yourDealer.

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IMPACT DAMAGE

Your engine has a shock absorption system de-signed to help withstand damage from impact withunderwater objects at low to moderate speeds.However, high speed impacts with rigid underwaterobjects like pilings or boulders can be beyond thecapability of the absorption system. Such impactscan result in serious damage to your engine and in-jury to boat occupants from the engine or its partsentering the boat. Occupants can also be ejected orinjured by falling against portions of the boat as aresult of rapid deceleration following impacts. Whenboating in unfamiliar, shallow, or debris-laden wa-ters, seek information on safe boating areas andnavigation hazards from a reliable local source. Re-duce your speed and keep a sharp lookout!

The engine’s shock absorption system does notwork while operating in reverse. If you back into anobject, either in the water or while trailering, yourboat and engine can be seriously damaged.

If you hit any object, stop immediately and examinethe engine for loosening of attaching hardware andclamp screws, if equipped. Inspect for damage toswivel and stern brackets, steering components,and components in the area of impact. Also, exam-ine the boat for structural damage. Tighten anyloosened hardware. If the collision occurred in thewater, proceed slowly to harbor. Before boatingagain, have your Dealer thoroughly inspect all com-ponents.

STORING

To avoid difficulty when restarting, never run theengine with the fuel hose disconnected or run theengine 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.

WARNINGFailure to inspect for damage could result insudden, unexpected component failure,loss of boat control, and personal injury.Unrepaired damage could reduce your boatand engine’s ability to resist future impacts.

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SPECIAL OPERATING CONDITIONS

Salt WaterFlush the engine internally after use in salt, pollutedor brackish water to help prevent mineral depositsfrom clogging cooling passages. Your outboard hasa built-in flushing port to facilitate flushing. Refer toFlushing.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 outof the water — except in freezing temperatures.Upon removal from salt water, leave it in a verticalposition until its cooling system has drained.

Weedy WaterWeeds block water intakes and cause your out-board to overheat. Weeds on the propeller createvibration and reduce boat speed.Run at slow speeds and in REVERSE frequently toclear 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 athigher speed.

Boat Bottom and Engine External FinishThe condition of your boat’s bottom affects perfor-mance. A covering of marine growth reducesspeed. For maximum performance, keep the boat’srunning surface clean by wiping it dry after each useand 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 withsoapy water and apply a coat of automotive wax.Leave the engine cover in place when washing theoutboard.

High Altitude

IMPORTANT: Your engine’s EMM will automatical-ly compensate for changes in altitude. However, ifyou consistently boat above 3000 ft. (900 m), youmay experience a slight loss of power due to re-duced air density.If your engine drops below the recommended RPMoperating range at full throttle, have your Dealer se-lect a lower pitch propeller.If you return to sea level, have your Dealer installthe original propeller and verify correct RPM oper-ating range.

Shallow Water

IMPORTANT: Serious engine damage will occur ifthe gearcase is allowed to drag on the waterwaybottom.

Freezing WeatherDURING operation in freezing weather, keep thegearcase submerged at all times.Upon removing your motor from the water, leave itin a vertical position until its cooling system isdrained.

IMPORTANT: Water that has leaked into the gear-case, or remained in the cooling system or othercomponents can freeze, causing serious enginedamage.

IMPORTANT: If your outboard’s gearcase isequipped with an integral speedometer pickup, allwater must be cleared from the hose to preventgearcase damage. Refer to Off-Season Storage.

Submerged EngineIf your engine has been under water, have it ser-viced immediately upon recovery. If immediateservice is unavailable, resubmerge it in fresh waterto avoid prolonged exposure to the atmosphere.After submersion, all boat and engine electrical, fu-el, and oiling systems must be inspected for signsof water intrusion. Your Dealer should perform thisservice.

Dual Engine OperationWhen you are maneuvering at slow speed, be sureboth engines are running, even if one or both are inNEUTRAL.If it is necessary to return to harbor with one enginenot running, you should not attempt to operate theboat above planing speed. Tilt the inoperative en-gine high enough to keep its propeller out of the wa-ter.

Under TowShould you require a tow from another boat:• Shift your engine to NEUTRAL;• Tilt its gearcase out of the water; and• Off-load all persons into another boat.Keep towing speed slower than planing speed.

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MAINTENANCE

Maintenance, replacement, or repair of theemission control devices and systems may beperformed by any marine SI (spark ignition) en-gine repair establishments or individual.

ENGINE EMISSIONS INFORMATION

Manufacturer’s ResponsibilityBeginning with 1999 model year engines, manufac-turers of marine engines must determine the ex-haust emission levels for each engine horsepowerfamily and certify these engines with the UnitedStates 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 ResponsibilityWhen performing service on all Johnson outboardsthat carry an emissions control information label,adjustments must be kept within published factoryspecifications.Replacement or repair of any emission relatedcomponent must be executed in a manner thatmaintains emission levels within the prescribed cer-tification standards.Dealers are not to modify the engine in any mannerthat would alter the horsepower or allow emissionlevels to exceed their predetermined factory speci-fications.Exceptions include manufacturer’s prescribedchanges, such as altitude adjustments, for exam-ple.

Owner ResponsibilityThe owner/operator is required to have enginemaintenance performed to maintain emission levelswithin prescribed certification standards.The owner/operator is not to, and should not allowanyone to, modify the engine in any manner thatwould 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 factorysettings or specifications will void the product war-ranty.

EPA Emission Regulations

All new 2002 and more recent Johnson outboardsmanufactured by BMCA are certified to the EPA asconforming to the requirements of the regulationsfor the control of air pollution from new watercraftmarine spark ignition engines. This certification iscontingent on certain adjustments being set to fac-tory standards. For this reason, the factory proce-dure for servicing the product must be strictlyfollowed and, whenever practicable, returned to theoriginal 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 theEPA requirements on exhaust emissions for marineproducts. For more detailed information on this sub-ject, you may contact the following locations:

VIA U.S. POSTAL SERVICE:

Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance ProgramsGroup (6403J)401 M St. NWWashington, DC 20460

VIA EXPRESS or COURIER MAIL:

Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance ProgramsGroup (6403J)501 3rd. St. NWWashington, DC 20001

EPA INTERNET WEB SITE:

www.epa.gov

WARNINGOnly perform service procedures which aredetailed in this Operator’s Guide. Attempt-ing to perform maintenance or repair onyour outboard if you are not familiar withthe correct service and safety procedurescould cause injury or death.

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10-HOUR INSPECTION

After 10 hours of operation, your new engine will bebroken in and its mechanical parts will have seated.At that time, all systems should be checked and anyadjustments needed should be made.Your Dealer will perform this 10-Hour Inspection atyour 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 engineonce a year or after each 100 hours of operation,whichever comes first.

OFF-SEASON STORAGE

You must protect against natural environmentalconditions that can be damaging to an outboardmotor. Temperature and humidity changes whileyour 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 theengine will oxidize and weather which can result inloss of octane and can cause gum deposits in thefuel system. Your warranty does not cover enginefailure caused by these conditions. We strongly rec-ommend that you have your Dealer prepare youroutboard for the off-season.To do the off-season storage preparations yourself,gather the supplies and perform the following steps:

2+4 fuel conditionerTriple-Guard greaseUltra-HPF gearcase lubricantStorage Fogging Oil spray canEvinrude/Johnson Ultra 4-Stroke syntheticblend oil

Stabilize the engine’s fuel supply with 2+4 fuel con-ditioner during the last hours of operation to ensureproper stabilization, following instructions on thecontainer for mixture. Be sure to run the enginelong enough for the treated fuel to reach the en-gine.

IMPORTANT: Provide a water supply to the engineand 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 theengine with the fuel hose disconnected or run theengine out of fuel.

Oil and Filter — Start the engine and run it atleast five minutes to warm the crankcase oil.Stop the engine and drain the crankcase while theengine is warm. Refill it with Evinrude/Johnson Ul-tra 4-Stroke synthetic blend oil. Replace the oil fil-ter. Refer to Crankcase Oil and Filter. Restart theengine and run it for a few minutes to circulate thefresh oil.

IMPORTANT: It is very important that the bearingsurfaces be coated with clean oil before entering aperiod 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 SparkPlugs.Spray Evinrude/Johnson Storage Fogging Oil intothe spark plug holes.Slowly rotate the flywheel by hand to distribute thefogging oil and to drain the water from the waterpump.Install spark plugs; tighten to specifications inSpark Plugs.

Fuel filter(s) — 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.

WARNINGPrevent 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 flushingdevice.

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Screws, bolts, nuts — Tighten any that areloose.

Propeller — Remove and examine. If damaged,see your Dealer. Clean the propeller shaft and lubri-cate it. Refer to Propeller.

Gearcase speedometer pickup, if equipped —Disconnect the speedometer hose at the upperconnection. With air pressure no more than 25 psi(167 kPa), blow all water from the gearcase speed-ometer pickup system. Reconnect speedometerpickup after all the water has been removed.

Lubrication — Refer to Lubrication to drain andrefill the gearcase and for lubricating points on theengine.Touch up painted surfaces and wax the engine’sexterior. Store the engine on the boat (or an enginestand) in a vertical, self-draining position.If you cannot store the engine in the recommendedvertical position, be sure the cooling system isdrained completely.

IMPORTANT: Never place the gearcase higherthan the powerhead. Any water remaining in the ex-haust passages can run into the cylinders andcause serious damage.If you remove an "installed" engine, examine allhardware 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 conditionand water level, then charge it. Store it in a placethat’s cool and dry, out of direct sunlight. Check thewater level and charge it periodically during thestorage period.

Portable fuel tank — Disconnect the hose fromthe 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 thehose to protect it.

WARNINGStore fuel tanks in a well-ventilated area,away from heat and open flame. Preventescape of liquid or vapors which could acci-dentally ignite. Close the filler cap ventscrew, if equipped. Be sure the discon-nected fuel hose does not drip.

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PRE-SEASON SERVICE

Remove your outboard from storage and prepare itfor a season of reliable service by performing a gen-eral check and a few preventive maintenance pro-cedures.Examine all loosened or removed hardware andany steering, throttle, and shift systems. Replacedamaged or missing parts with Evinrude/JohnsonGenuine Parts or equivalent.

Engine Oil — Check the engine oil level. Refer toCrankcase Oil and Filter.With the propeller removed, check the gearcase forleakage. If leakage is evident, the gearcase sealsshould be replaced. See your Dealer.

Anticorrosion anodes — Check condition. Referto Anticorrosion Anodes.Install the propeller unless you will run the engineon a flusher for your pre-season servicing. If so, in-stall the propeller after you shut OFF the engineand disconnect the flusher. Refer to Flushing.Refer to Propeller to install the propeller.

Top off fuel tank with fresh fuel.

Battery — Charge fully and install. Refer to Bat-tery.

Refer to Engine Monitoring and review your en-gine’s warning system self-test routine. During yourpreseason start-up, make sure the warning systemself-tests properly. If it does not, see your Dealer.Follow Engine Starting and start the engine. Let itidle while you:Observe running quality – if poor, refer to TroubleCheck Chart or see your Dealer.Observe water pump operation. Water must flowfrom the water pump indicator in a steady stream. Ifit does not, shut OFF the engine and investigate.Refer to Engine Overheating.Stop the engine and check the fuel system forleaks.

WARNINGFailure to carefully reattach the outboardand its control systems with factory-speci-fied hardware can result in sudden, unex-pected loss of boat control.

WARNINGPrevent accidental contact with a rotatingpropeller; always remove it when using aflusher to run the engine.

WARNINGDo not use a booster battery and jumpercables to start the engine. Fumes ventedcan cause explosion and fire, resulting inproperty damage, serious injury, or death.

WARNINGFailure to check for fuel leakage could allowa leak to go undetected, resulting in fire orexplosion.

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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 orexceed 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.

InstallationRead and understand the safety information sup-plied with your battery BEFORE you begin installa-tion.

IMPORTANT: Place the battery in a hold-downsystem and in a location that is easily accessible forfrequent checking and recharging.Place a large-surface star washer over the battery’spositive (+) post. Stack the RED battery cable fromthe motor on the star washer, then install cablesfrom accessories (if any). Finish the connectionwith a hex nut and tighten it firmly with a wrench.Connect the motor’s BLACK battery cable to thebattery’s negative (–) post in the same manner.

1. Large surface star washer2. Cover

Tighten all connections securely and coat the in-stallation with Triple-Guard grease.

IMPORTANT: DO NOT use wing nuts on batteryconnections even if they came with the battery.Wing nuts can loosen and cause errant warningsignals 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 contactingeither battery post.

IMPORTANT: Service electrical components onlywhile the outboard is NOT running. Be careful whenidentifying positive and negative battery cables andposts. If you touch the wrong post with a battery ca-ble, even briefly, the charging system will be dam-aged.

WARNINGKeep the battery connections clean, tightand insulated to prevent their shorting orarcing and causing an explosion. If the bat-tery mounting system does not cover theconnections, install covers. Check often tosee that connections stay clean and tight. WARNING

Battery electrolyte is acidic — handle withcare. If electrolyte contacts any part of thebody, immediately flush with water and seekmedical attention.

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CRANKCASE OIL AND FILTER

Initial Fill

IMPORTANT: 4-Stroke outboards are shippedwithout oil in the crankcase. You must add oil tothe crankcase before starting the engine for thefirst time. It is recommended you add Evinrude/Johnson 4-Stroke outboard oil. Refer to Changingthe Oil for acceptable substitute lubricants.BEFORE filling the crankcase for the first time, besure it is empty by checking the dipstick. Refer toChecking.After the first 10 hours of operation, replace thebreak-in lubricant with Evinrude/Johnson Ultra 4-Stroke synthetic blend oil. Refer to 10-Hour In-spection.

CheckingCheck 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 the dipstick, wipe it clean, and install

it.3) Move the dipstick again and locate the line of

oil. If the line of oil is not between the ADDand the FULL marks, you must add or re-move oil as indicated. If the line of oil level isnear the lower limit, add enough oil to raisethe level to the upper limit.

1. Add2. Full

4) Securely install the dipstick and wipe up anyspilled oil.

IMPORTANT: Operating the engine with too muchor too little oil in the crankcase will damage it.

Changing the FilterSee your Dealer.

Changing the OilRefer to Engine Maintenance and InspectionSchedule for frequency.After the first 10 hours of operation, replace thebreak-in lubricant with Evinrude/Johnson Ultra 4-Stroke synthetic blend oil. Refer to 10-Hour In-spection.If Evinrude/Johnson Ultra 4-Stroke synthetic blendoil is temporarily unavailable, you may useEvinrude/Johnson 4-Stroke outboard oil or anequivalent FC-W-approved 10W-40 or 10W-50 oil.Drain (or siphon) the old oil after running the engineto warm it. Warm oil flows more quickly and com-pletely, containing more suspended sludge thancold oil. If you change the oil only once a season,time the work so the engine contains clean oil dur-ing storage.

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

12

CAUTIONUsed motor oil may be harmful. Avoid pro-longed and repeated skin contact. Washaffected skin with soap and water.

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3) Hold a suitable container under the oil drainscrew. Remove the screw and drain the re-servior. Before you reinstall the screw, re-place the gasket with a new one (severalwere included in your tool kit). Reinstall thescrew and tighten it securely.

1. Oil drain screw2. Gasket

4) Pour the recommended oil into the oil fill untilit reaches the upper mark on the dipstick. Re-fer to Engine Specifications for crankcasecapacity.

5) Replace the oil fill cap and clean any spilledoil off the engine and your skin.

6) Reinstall the upper cover.7) Supply water to the cooling system and run

the engine at idle to check for leaks, especial-ly around drain screw and oil fill cap. Correctany problems.

8) Stop the engine and recheck crankcase oillevel using the dipstick. Add oil as indicated.

1. Add2. Full

Dispose of used oil in a reasonable manner follow-ing all local regulations.

ADJUSTMENTS

Trim Tab

A propeller will generate steering torque when thepropeller shaft is not running parallel to the water’ssurface. The trim tab is adjustable to compensatefor 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 tothe left or right when its load is evenly distributed,adjust the trim tab as follows:With the motor shut OFF, loosen the trim tabscrew. If the boat pulled to the right, move the rearof the trim tab slightly to the right. If the boat pulledto the left, move the rear of the trim tab slightly tothe left.

Tighten the trim tab screw securely.Test the boat and, if needed, repeat the procedureuntil steering effort is as equal as possible.

1

2

12

WARNINGImproper trim tab adjustment can cause dif-ficult steering.

The trim tab is also an anti-corrosion anode.Disintegration of the anode can effect boathandling and performance. Make sure thetrim tab is in good condition and adjustproperly.

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High motor installations — The trim tab mightbe above the water when the motor is trimmed out.Steering effort might increase. Steering effort willbe reduced if you trim the motor in and submergethe trim tab.

Dual standard rotation motors — Move both ofthe trim tabs equally and in the same direction.

Dual motors (one counter and one standard ro-tation) — Set both trim tabs to the center position.

Throttle FrictionAdjust throttle friction on your remote control tomaintain its position and prevent unwanted throttle“creep” under normal operating conditions.To adjust, start engine and move control handleinto FORWARD throttle range. While underway,turn adjustment knob clockwise to increase friction.The friction adjustment is effective only in theFORWARD throttle range.

1. Throttle friction control

See your Dealer for throttle friction adjustments onyour specific remote control.

LUBRICATION

GearcaseReplace gearcase lubricant after first 10 hours ofoperation. Check level and condition of lubricant af-ter next 50 hours of operation. Add lubricant if nec-essary.Thereafter, check level and condition of lubricantevery 50 hours. Replace lubricant every 100 hoursof operation or once each season, whichever oc-curs first. Refill with Ultra-HPF gearcase lubricant.If not available, Hi-Vis™ or other marine gearcaselube can be used, however, long term durabilitymay be affected with continued use. See your Deal-er.

IMPORTANT: The recommended gear lubricantsinclude special additives for marine applications.Do not use automotive gear lubricants, 2-stroke or4-stroke engine oil, or any other oil or grease forgearcase applications.With motor in normal operating position:1) Remove drain/fill plug and lubricant level plug

from side of gearcase and completely draingearcase of old lubricant.

2) Examine drained lubricant for metal filings,milky appearance, or black color with burntodor. If old lubricant has any of those charac-teristics, see your Dealer. If drained lubricantis in good condition, continue.

3) Place tube of lubricant in drain/fill hole and fillslowly until lubricant appears at lubricant lev-el hole. See Engine Specifications for gear-case capacity.

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4) Install lubricant level plug before removingtube from drain/fill hole. Drain/fill plug canthen be installed without loss of lubricant.

5) Securely tighten both plugs.

1. Drain/fill plug2. 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 lubricantup to the correct level.

Steering SystemThe installer was instructed to grease the steeringcable ram during installation. Periodic regreasing ofthe steering cable ram with Triple-Guard grease isrequired. Refer to Engine Maintenance and In-spection Schedule for lubrication frequency. Referto steering system manufacturer’s informationwhen servicing boat’s steering system.

1. Steering, tilt tube

Power Trim and Tilt Fluid ReservoirTilt the motor up and engage the tilt support. De-pending on your model, refer to Power Trim andTilt. Remove filler cap and check fluid level. If nec-essary, add enough Evinrude/Johnson Power Trim/Tilt and Power Steering Fluid to bring the fluid leveleven with the bottom of the fill cap hole when theunit is at full tilt.

1. Tilt support2. Filler cap

IMPORTANT: Correct fluid level must be main-tained to ensure operation of the impact protectionbuilt into this unit.

Lubrication PointsRefer to Engine Maintenance and InspectionSchedule for lubrication frequency and recom-mended lubricant.

1. Swivel bracket, tilt support

WARNINGFailure to regrease as recommended couldresult in steering system corrosion. Corro-sion can affect steering effort, making oper-ator control difficult.

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1. Throttle and shift linkage

WATER PRESSURE

An optional water pressure gauge is recommendedto monitor cooling system pressures. Noticingchanges in water pressure can help prevent engineoverheating. The water pressure gauge must beconnected at the correct point to ensure the mostaccurate pressure readings. Follow the installationinstructions included with the water pressuregauge.

FUEL LINE FILTER

It is recommended a water-separating fuel filter beinstalled to help prevent water that may be presentin the outboard’s fuel tank. Water in the fuel tankcan damage your outboard’s fuel injection system,causing poor engine performance. Refer to EngineMaintenance and Inspection Schedule for fre-quency.An authorized Evinrude/Johnson Dealer shouldservice the fuel filter.

IMPORTANT: A restricted fuel delivery system willnot allow the engine fuel pump to deliver sufficientfuel under all conditions. This can result in loss ofperformance and possibly engine damage.

1. Filter

FUSES

IMPORTANT: Always carry spare fuses. Use thespare fuse holder to hold an extra fuse.

1. Fuse2. Spare fuse holder

Fuse Failure

A minor electrical problem can blow a fuse. Re-place it with a fuse of the same rating.Repeated failures of fuses in the same position in-dicate a serious problem. Do not replace it withhigher rated fuses; see your Dealer for service.

1

Fuse Description30-Amp Sub Fuse60-Amp Main Fuse

1

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SPARK PLUGS

Inspect spark plugs periodically. Replace if elec-trodes are badly worn, insulators are cracked, or ifthey are badly fouled.To remove spark plugs, twist and remove all sparkplug leads. Unscrew spark plug from cylinder head.To install spark plugs, wipe spark plug seats cleanwith a clean rag. Install spark plugs finger tight, thentighten to specified torque. Refer to Engine Speci-fications.

IMPORTANT: Avoid engine damage by installingspark plugs into COOL cylinder head and not over-tightening.Before installing the spark plug lead, apply a lightcoat of Triple-Guard grease to the ribbed portion ofthe spark plug. This will help prevent corrosion be-tween the spring terminal and the spark plug.

1. Ribbed portion of the spark plug

PROPELLER

IMPORTANT: Apply Triple-Guard grease to the en-tire propeller shaft before installing the propeller. Atleast annually, remove the propeller and check fordebris. Clean the shaft and regrease it before rein-stalling a propeller.

InstallationSlide thrust washer onto shaft with shoulder facingaft.Slide propeller onto shaft, engaging the splines andseating it on the thrust washer.Slide spacer onto the shaft and engage the propel-ler shaft splines.Slide washer onto propeller shaft.Wedge a block of wood between the propellerblade and the anti-ventilation plate.

Install propeller nut and tighten to a torque of 36 to43 ft. lbs. (50 to 60 N·m).

WARNINGThe ignition system presents a seriousshock hazard. The primary circuit operatesin excess of 250 volts; the secondary circuitoperates in excess of 25,000 volts. Use cau-tion to avoid injury from shock or injuryresulting from your reaction to shock. Donot handle primary or secondary ignitioncomponents while the engine is cranking orrunning.

1

WARNINGWhen servicing the propeller, always shiftthe outboard to NEUTRAL position, turn thekey switch OFF and disconnect battery pos-itive (+) cable so the engine cannot bestarted accidentally.

Maintenance - 45

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Continue to tighten propeller nut until nut slots andcotter pin hole are aligned. Install new cotter pinand bend ends to secure.

1. Thrust bushing2. Spacer3. Washer4. Cotter pin5. Propeller nut

Remove block of wood. Make sure engine is inNEUTRAL; give propeller a spin. It must turn freely.

RepairIf your propeller hits a solid object, the impact is par-tially absorbed by the rubber bushing in the hub tohelp prevent damage to the engine. A strong impactcan damage the hub and propeller blades. Damageto 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 tosmooth slight damage to blade edges. See yourDealer for repair of serious damage.

ANTICORROSION ANODES

Your motor is equipped with one or more anodesthat protect it from galvanic corrosion. Refer to Fea-tures for anode location. Disintegration of the an-ode is normal and indicates it is working. Checkeach anode periodically. Replace anodes smallerthan 2/3 their original size. See your Dealer for re-placements.

1. Anode

1. Anode

Galvanic corrosion destroys underwater metalparts and can occur in fresh or salt water; however,salt, brackish and polluted waters will acceleratecorrosion.Metal-based antifouling paint on the boat or motorand the use of improperly installed shore power inthe area of your moored boat will also acceleratecorrosion.

IMPORTANT: NEVER paint the anode, its fasten-ers, or its mounting surface. Painting will reduce itscorrosion protection.

1

23

4

5

1

1

1

46 - Maintenance

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BONDING WIRES

Bonding wires are used to electrically connect theengine components so they exist in a commonground circuit. This allows them to be protectedagainst electrolysis by the anodes. These wires andtheir terminals should be checked periodically to besure they have not been damaged.

MOTOR REMOVAL AND TRANSPORTING

Motor RemovalIf it is necessary to remove the outboard from theboat, we strongly recommended your Dealer per-form the service.

Motor Transporting

Vertical transport

Attach the clamp bracket to a stand by securingtransom bolts.

Horizontal transport

Drain the crankcase oil. Refer to Crankcase Oiland Filter.

Drain the gasoline from the vapor separator as fol-lows:1) Remove the motor cover and rubber seal.2) Remove the seven bolts on the starboard cov-

er, then remove cover.3) Pull the drain hose end out.4) Loosen the vapor separator drain screw and

drain the gasoline into a suitable container.

1. Drain hose2. Drain screw

5) After draining, retighten the drain screw and re-install all components.

Rest the outboard on a case protector, starboardside down.Do not rest the engine before the engine oil hasdrained, as oil may enter the cylinder from the sumpand outer casings may be damaged.

IMPORTANT: Do not rest the engine before thecooling water has drained completely, as watermay enter the cylinder through the exhaust port andcause problems.

IMPORTANT: Do not let the gearcase of the out-board sit higher than the powerhead during trans-porting or storing. Water may drain into thepowerhead, causing damage to the engine.

WARNINGUse a proper, safe container to store anygasoline drained from the outboard motor.

1

2

Maintenance - 47

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TROUBLE CHECK CHART

IMPORTANT: If you are unable to identify or solve the problem, contact your Dealer.

SYMPTOM POSSIBLE CAUSE

Starter motor will not operate • Shift handle not in NEUTRAL.• Battery and electrical connections loose or corroded.• Fuse blown. Refer to Fuses.• 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.• Engine flooded. Raise fast idle lever and crank engine in 10-sec-

ond periods.• Spark plugs incorrect. Refer to Engine Specifications.• Spark plugs improperly gapped, carboned, burned or wet.• Fuse blown. Refer to Fuses.• 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.

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. • S.L.O.W. protection mode activated. Refer to Engine Monitor-

ing.

Engine runs, but makes little or no progress

• Propeller hub loose, slipping.• Propeller blades bent or missing.• Propeller shaft bent. • Propeller fouled and restricted.

Warning System Activates • Refer to Engine Monitoring.

48 - Maintenance

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NOTES

Maintenance - 49

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ENGINE MAINTENANCE AND INSPECTION SCHEDULE

Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to theproduct’s life span. The following maintenance chart provides guidelines for engine maintenance and in-spection scheduled to be performed by you and/or by an authorized Dealer. The schedule should be ad-justed according to operating conditions and use.The recommended lubricants have been formulated to protect bearings, gears and engine components.They must be used to avoid damage caused by improper lubrication.

IMPORTANT: Schedules for rental operations, commercial applications or high hour use will requiregreater frequency of inspection and maintenance.

Engine Maintenance and Inspection Schedule

DescriptionEngine Care Product

Frequency

Eac

h U

se

10-H

ou

r In

spec

tio

n

Eve

ry 5

0 H

ou

rs

or

6 m

on

ths

Eve

ry 1

00 H

ou

rs

or

An

nu

ally

Eve

ry 2

00 H

ou

rs

or

Bia

nn

ual

ly

Mechanical steering, lubricate (1) 7 Every 60 days / Every 30 in Saltwater

Tilt tube, inspect and lubricate (1) 7 Every 60 days / Every 30 in Saltwater

Swivel bracket / tilt support bracket, inspect and lubricate (1)

7 Every 60 days / Every 30 in Saltwater

Throttle and shift linkage, inspect and lubricate (1) 7 Every 60 days / Every 30 in Saltwater

Remote control cables, lubricate (1) 7 Every 60 days / Every 30 in Saltwater

Lubrication and corrosion protection for metallic components

4 Every 60 days / Every 30 in Saltwater

Battery connections and condition, verify 7 O D

SystemCheck self-test and warning horn, verify operation

O D

Anticorrosion anodes, verify operation O D

Water intake screens, verify condition O D

Overboard water pump indicator, verify operation O D

Steering system check, verify function O D

Throttle and shift operation, verify function O D

Emergency stop circuit and lanyard, verify function O D

Crankcase oil level, check O D

Flush cooling system O

Operator’s Guide, onboard O

Engine upper and lower motor covers, clean and wax O

Operator’s Guide, review O

Fuel and oil system components, inspect and repair leaks (2)

D D

Fastener inspection, tighten loosened components D D

Gearcase lubricant, replace 5 D D

Thermostat, inspect and verify operation (2) D D

Power tilt/trim fluid, inspect fluid level 6 D D

Engine to transom mounting hardware, re-torque D D

Electrical and ignition wires and connections, inspect D D

50 - Maintenance

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Powerhead synchronization and linkage, inspect (2) 7 D D

Access EMM information, resolve service codes D D

Breather line, inspect D D

Crankcase oil, replace (3) 11 D D

Valve tappet clearance, inspect (2) D D

Crankcase oil filter, replace D D

Bonding wires, inspect D

Gearcase lubricant, inspect fill level and condition of lube

5 D

Starter pinion shaft, inspect and lubricate (4) 9 D

Propeller shaft splines, inspect and lubricate 7 D

Spark plugs, replace (2) D

Decarbonize 10 D

Timing belt, inspect D

Driveshaft splines, inspect and lubricate 8 D

Water pump, inspect and replace D

Ignition timing, check D

Fuel mixture, check D

Low pressure fuel filter, replace D Every 400 hours or biannually

Timing belt, replace D Every 800 hours or four years

High pressure fuel filter, replace D Every 1000 hours

(1) Also recommended at 10-Hour Inspection

(2) Emission-related component

(3) Replace every 100 hours or annually if Evinrude/Johnson Ultra 4-Stroke synthetic blend oil is not used

(4) Do not use light duty penetrating lubricants

D Dealer Performed Service

O Operator Performed Service

4 Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1” multi-purpose lubricant

5 Ultra-HPF gearcase lubricant

6 Power Trim/Tilt Fluid

7 Triple-Guard grease

8 Evinrude/Johnson Molylube P/N 175356

9 Starter Bendix Lube Only P/N 337016

10 Evinrude/Johnson Engine Tuner

11 Evinrude/Johnson Ultra 4-Stroke synthetic blend oil

Engine Maintenance and Inspection Schedule

DescriptionEngine Care Product

Frequency

Eac

h U

se

10-H

ou

r In

spec

tio

n

Eve

ry 5

0 H

ou

rs

or

6 m

on

ths

Eve

ry 1

00 H

ou

rs

or

An

nu

ally

Eve

ry 2

00 H

ou

rs

or

Bia

nn

ual

ly

Maintenance - 51

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Bombardier Recreational Products

52 - Maintenance

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CHANGE OF ADDRESS / CHANGE OF OWNERSHIPIf your address has changed or if there has been a change of ownership, be sure to fill out and mail thecard provided on this page.Such notification is likewise necessary for your own safety even after expiration of the original warranty,since BMCA will be in a position to contact you if correction to your outboard becomes necessary.Outside the U.S. and Canada, this card should be sent to the Bombardier Recreational Products divisionwhere the outboard was registered. Please contact your Dealer or distributor.

000063

Change of address Change of ownership

Model number

Serial Number

Old address / Previous owner

Last name

First name M.I.

Address

City State

Zip code Country

Phone number

Signature Date

New address / New owner

Last name

First name M.I.

Address

City State

Zip code Country

Phone number

Signature Date

Maintenance - 53

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Bombardier Motor Corporation of America

54 - Maintenance

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Bombardier Recreational Products

Maintenance - 55

Page 58: Johnson 140

Operator’s GuideConfirmation of Receipt

Your Dealer

Upon delivery of your new Evinrude/Johnson Outboard, complete and sign the form hereunder. YourDealer will take receipt of the form for their records.

Receipt

Name:

Address:

Name:

Address:

Owner of Model No:

Serial No:

(To be completed by customer or selling Dealer)

The Dealer named on this document has instructed me on the operation, maintenance, safety features, and warranty policy, all of which I understand and agree to be bound with. I am also satisfied with the predelivery set-up and inspection of my Evinrude/Johnson Outboard. I have also received a copy of the Operator’s Guide.

Signature:

Date:

56 - Maintenance

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Readiness Test and a Final Word to the Owner/OperatorThe Operator’s Readiness Test....

1. Did you read this Guide from front cover to rear cover?

2. Are you ready to take responsibility for the safe operation of your boat and motor?

3. Do you understand all the safety precautions and instructions contained in this Guide?

4. Do you understand that this Guide contains essential information to help prevent personal injury anddamage to equipment?

5. Are you ready to follow the recommendations in this Guide and take a boating safety course beforeyou operate your boat and motor?

6. Do you know who to ask if you have any questions about your boat and motor?

7. Do you know your local marine traffic laws?

8. Do you understand that human error can be caused by carelessness, fatigue, overload, preoccupa-tion, unfamiliarity of operator with the product, drugs and alcohol, just to name a few?

WARNINGIt 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 Guidewill build good judgment when boating. Always be alert and careful: a good foundation forsafety.

Page 60: Johnson 140

*5035765*

WARNINGRead this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always have this Operator Guide onboard.

! !

R4, RL4

4 Stroke4/5/6 HORSEPOWER

2005