Johnson R, Operator'S Manual

Page 1: ...2004 R RL RH RHL TE TEL 9 9 10 15 HORSEPOWER Operator s Guide ...

Page 2: ...d can be significant We strongly believe the rewards for following our recommendations will be worthwhile Remember that YOU are the key to safety Good safety practices not only protect you but also protect the people around you Having fun is what it s all about and with your cooperation the pertinent information in this Guide can en sure a safe and enjoyable experience Enjoy the great outdoors on ...

Page 3: ...FUEL AND OIL 14 FUEL 14 OIL 15 ADDITIVES 15 FUEL OIL RATIO 15 MIXING FUEL AND OIL 15 FUEL SYSTEMS 16 BREAK IN 10 HOURS 16 ENGINE STARTING 17 BEFORE START UP 17 ENGINE STOPPING 20 SHIFTING AND SPEED CONTROL 21 EMERGENCY STARTING 21 FUEL ECONOMY 23 OPERATION 24 MOTOR ANGLE ADJUSTMENT 24 TRAILERING 24 TILTING AND TILT SUPPORT 24 SHALLOW WATER DRIVE 25 PROPELLER SELECTION 26 MOORING 26 FLUSHING 27 ENG...

Page 4: ...ANGER Indicates an imminently hazardous situa tion which if not avoided WILL result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided CAN result in severe injury or death CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate personal injury or property dam age It also may be used to alert against u...

Page 5: ...s adhere to the fueling procedure contained in this Operator s Guide and those given to you by the fueling station Always verify fuel level before use and during the ride Apply the principle of 1 3 fuel to des tination 1 3 back and 1 3 reserve fuel supply Do not carry spare fuel or flammable liquids in any storage or engine compartments Do not operate your boat if you are under the influence of dr...

Page 6: ...ard s Model Number ___________________________ Serial Number ____________________________ Purchase Date ___________________________ Ignition Key Number _______________________ Stolen Outboards North America Report your outboard as stolen to Customer and Dealer Support Services 250 Sea Horse Drive Waukegan IL 60085 U S A Give the outboard s model and serial numbers and enclose a copy of the police ...

Page 7: ... outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred Dealer and then only after the Bombardier specified pre delivery inspection process has been com pleted and documented by the purchaser and Dealer Warranty coverage only becomes available upon proper registration of Product by Dealer or owner Only the orig...

Page 8: ...f fuses zinc anodes thermostats timing belts starter motor bushings trim motor brushes filters propellers propel ler bushings and spark plugs Damage caused by improper or lack of installation maintenance winterization and or storage failure to follow the procedures and recommendations in the Operator s Guide Damage resulting from removal of parts improper repairs service maintenance or modificatio...

Page 9: ... GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE OR PROVINCE TO PROVINCE No distributor Dealer or any other person is authorized to make any affirmation representation or war ranty regarding Product other than those contained in this limited warranty and if made shall not be en forceable against Bombardier Bombardier reserves the right to modif...

Page 10: ...mited Warranty see your Bombardier distributor dealer authorized to distribute Johnson 2 stroke products in the country in which the sale occurs If further assistance is required please contact Bombardier Customer Support Services 250 Sea Horse Drive Waukegan Illinois 60085 or the affiliate of Bombardier where the Product was registered for war ranty ...

Page 11: ...General Information 9 NOTES ...

Page 12: ... Button 3 Anticorrosion Anode 13 Shift Lever 4 Lubricant Drain Fill Plug 14 Neutral Indicator 5 Lubricant Level Plug 15 Choke Knob 6 Battery Cable 1 16 Starer Handle 7 Clamp Screws 17 Manual Starter 8 Carrying Handle 18 Flushing Inlet Screw 9 Tilt Friction Nut 19 Fuel Tank 10 Start Button 1 1 Electric Start Models 4 5 6 9 8 10 11 12 13 14 15 16 17 18 7 3 2 1 19 ...

Page 13: ... Speed Adjustment 34 Antiventilation Plate 24 Retention Lug 35 Lift Grip 25 Model and Serial Number Plate 36 Engine Cover Latch 26 Steering Friction Adjustment Screw 37 Spark Plugs 27 Clip and Lanyard Assembly 38 Starter Motor 1 28 Angle Adjusting Rod 39 Fuel Pump Filter 29 Shallow Water Drive Bracket 40 ECI Label 30 Positive Terminal Boot 1 1 Electric Start Models 33 34 29 28 27 26 25 24 35 36 37...

Page 14: ... Oil Ratio 50 1 Starting R RL RH RHL Rope start Battery Minimum 360 CCA 465 MCA OR 50 ampere hour 12 volts Spark Plug 2 Extended Low Speed Operation Torque Refer to ECI Label 9 9 only QL86C 0 030 in 0 8 mm Gap 18 to 21 ft lbs 24 to 28 N m AC Lighting 3 3 Available as optional kit 60 watts AC 12 volts Gearcase Lubricant Capacity Evinrude Johnson Ultra HPF gearcase lubricant 9 fl oz 260 ml Propeller...

Page 15: ...oping it DO NOT cut or retie the lanyard 1 Emergency stop switch 2 Clip An extra clip is provided another person can in sert it in the stop switch and start the motor in an emergency 1 Extra clip 1 2 WARNING Avoid knocking or pulling the clip off the stop switch during normal boating The resulting unexpected loss of forward motion can throw occupants forward caus ing injury Your emergency stop swi...

Page 16: ... Gasoline will oxidize and weather the result is loss of octane volatile compounds and the production of gum and varnish deposits which can damage the outboard WARNING Gasoline is extremely flammable and highly explosive under certain conditions Follow the instructions in this section explicitly Improper handling of fuel could result in property damage serious injury or death Always turn off the e...

Page 17: ... remove moisture from the fuel system It can be used continuously and should be used during any period when your engine is not being operated on a regular basis Its use will reduce spark plug fouling fuel system icing and fuel system component deterioration FUEL OIL RATIO New Engine During break in you must use a 25 1 4 oil fuel oil ratio in your fuel tank Refer to Break In 10 Hours Normal Operati...

Page 18: ...quipment Launch the boat and start the engine according to the procedures in Engine Starting Verify water pump operation often Look for a steady stream of water from the water pump indi cator If the stream of water stops shut off the en gine to prevent damage Find and correct the cause or see your DEALER before you continue Verify shift function by shifting into gear and ob serving that the boat m...

Page 19: ... the cover off unless you are performing maintenance and then be careful to keep hands hair and clothing clear of all moving parts Contact with moving parts could cause injury DANGER Contact with a rotating propeller is likely to result in serious injury or death Assure the engine and prop area is clear of people and objects before starting engine or operating boat Do not allow anyone near a prope...

Page 20: ...ent 2 Fuel primer bulb If equipped attach the clip and lanyard assembly to the emergency stop switch Snap the lanyard to se cure place on your clothing or life vest 1 Emergency stop switch Twist the throttle to SHIFT or slower 1 SHIFT Move the shift lever to NEUTRAL Refer to Shifting and Speed Control 1 2 1 2 WARNING Always shift to NEUTRAL before starting the engine to prevent sudden boat move me...

Page 21: ...otor starts To prevent damage to starter assembly allow starter cord to rewind be fore releasing starter handle If motor does not start refer to Trouble Check Chart 1 Starter handle 2 NEUTRAL Electric Start While seated press start button to START motor 1 START button 2 NEUTRAL Release start button as soon as engine starts If en gine does not start release button momentarily and then try again WAR...

Page 22: ...ater from the water pump indica tor is not visible stop the engine Refer to Engine Overheating IMPORTANT To avoid engine damage after start up do not exceed one quarter throttle less than 2000 RPM in NEUTRAL for extended periods of time Start up Warm Engine Follow Cold Engine procedure except warm en gines do not normally require use of the choke If engine fails to start use the choke ENGINE STOPP...

Page 23: ...Y STARTING If the starter cord breaks or the starter fails your en gine can be started using a piece of the starter cord or a 9 64 in 6 mm cord about 4 ft 1 2 m long WARNING Do not operate motor in REVERSE with the tilt run lever in TILT Motor may tilt out of the water resulting in loss of control 1 3 2 WARNING When using Emergency Starting proce dures the start in neutral only feature is inoperat...

Page 24: ...AL Twist Grip throttle is at START Pull latch and remove engine cover Electric Start Models Follow the procedures in Manual Start Models Manual Start Models Remove three screws that secure the manual start er 1 Screws 1 WARNING DO NOT use jumper cables and a booster battery to start engine Do not charge a bat tery in the boat with an external charger Fumes vented during either operation can lead t...

Page 25: ... Start up Cold Engine While seated pull hard on emergency starting cord to start motor After the motor starts run it at less than 2000 RPM in NEUTRAL for two minutes then reduce speed to an idle Do not attempt to replace manual starter or engine cover while engine is running If equipped snap emergency stop switch lanyard to a secure place on your clothing Proceed to nearest landing for service FUE...

Page 26: ...et TILTING AND TILT SUPPORT IMPORTANT Use the tilt grip to tilt your motor not the steering handle DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death DANGER Contact with a rotating propeller is likely to result in serious injury ...

Page 27: ...d by the position of the motor angle adjusting rod Relocate the motor angle adjusting rod if nec essary Refer to Motor Angle Adjustment Slow the engine and shift to NEUTRAL before en gaging or disengaging shallow water drive WARNING While engine is tilted leave tilt lever in the TILT position When the tilt run lever is in the RUN position tilt support can release unexpectedly and allow motor to dr...

Page 28: ...NEUTRAL Grasp tilt grip on engine cover and tilt motor slightly Shallow water drive bracket will automatically re lease Slowly lower motor to normal operating position PROPELLER SELECTION To select the correct propeller for your boating ap plication your boat and motor MUST be water test ed See your DEALER for assistance Refer to Propeller before removing or installing propeller IMPORTANT The corr...

Page 29: ...turn it so the water streams out to the side where it can be seen easily from the helm 7 Leave the outboard in vertical position long enough to completely drain the powerhead Outboard Not Running 1 The outboard may be in a tilted or vertical posi tion 2 Remove the plug from the flushing port 3 Install flushing device if needed and garden hose 4 Start the water and flush the engine for at least fiv...

Page 30: ...ntake screens 2 Water pump indicator If the stream of water from the water pump indicator becomes intermittent or stops reduce speed to idle and Shift to NEUTRAL SHUT OFF the engine Raise the engine Clean the water intakes and the water pump indi cator and Restart 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...

Page 31: ... stern brackets steering components and components in the area of impact Also exam ine the boat for structural damage Tighten any loosened hardware If the collision occurred in the water proceed slowly to harbor Before boating again have your DEALER thoroughly inspect all components STORING To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine o...

Page 32: ...t of automotive wax Leave the engine cover in place when washing the outboard High Altitude If you boat at altitudes above 3000 ft 900 m your engine might benefit from a lower pitched propeller different carburetor calibration or both See your DEALER IMPORTANT To avoid permanent powerhead damage be sure that an engine modified for high altitude operation is properly identified and returned to orig...

Page 33: ... the off season To do the off season storage preparations yourself gather the supplies and perform the following steps 2 4 fuel conditioner Triple Guard grease Ultra HPF gearcase lubricant Storage Fogging Oil spray can Stabilize the engine s fuel supply with 2 4 fuel con ditioner during the last hours of operation to ensure proper stabilization following instructions on the container for mixture B...

Page 34: ...e is evident the gearcase seals should be replaced See your DEALER Anticorrosion anodes Check condition Refer to Anticorrosion Anodes Install the propeller unless you will run the engine on a flusher for your pre season servicing If so in stall the propeller after you shut OFF the engine and disconnect the flusher Refer to Flushing Refer to Propeller to install the propeller Top off fuel tank with...

Page 35: ...ttery s negative post in the same manner 1 Large surface star washer 2 Cover Tighten all connections securely and coat the in stallation with Triple Guard grease IMPORTANT DO NOT use wing nuts on battery connections even if they came with the battery Wing nuts can loosen and cause errant warning signals or electrical system damage Service Before servicing the battery or the outboard re move both b...

Page 36: ...t at the factory with a range of adjustment provided If your engine dis plays poor running quality at low speed or idle ask your DEALER to perform the necessary adjust ments Tilt Friction The tilt friction nut should be adjusted ONLY enough to control return of gearcase from tilt to nor mal vertical position 1 Tilt friction screw Steering Friction The steering friction was set on your new motor be...

Page 37: ...tor in normal operating position 1 Remove drain fill plug and lubricant level plug from side of gearcase and completely drain gearcase of old lubricant 2 Examine drained lubricant for metal filings milky appearance or black color with burnt odor If old lubricant has any of those charac teristics see your DEALER If drained lubri cant is in good condition continue 3 Place tube of lubricant in drain ...

Page 38: ...remove the cover Do not lose O rings 1 Cover 2 Filter 3 O rings Wash filter with clean solvent blow dry Reinstall filter keeping lip of filter screen toward fuel pump body Install large O ring in its groove in the cover and the small O ring around center post of pump body Replace O rings if cut or damaged Reinstall cover Tighten cover screw securely clean up spilled fuel Check for leaks connect fu...

Page 39: ...re installing the propeller At least annually remove the propeller and check for debris Clean the shaft and regrease it before rein stalling a propeller Installation Slide thrust washer onto shaft with fish line trap groove facing forward Slide propeller onto shaft engaging the splines and seating it on the thrust washer Slide spacer onto the shaft and engage the propel ler shaft splines Wedge a b...

Page 40: ... cause unusual and excessive vibra tion Damage to the hub can cause excessive en gine RPM with little forward movement IMPORTANT Avoid or limit operation using a dam aged propeller Carry a spare propeller Keep your propeller in good condition Use a file to smooth slight damage to blade edges See your DEALER for repair of serious damage Fish Line Trap The thrust bushing contains a built up groove a...

Page 41: ...3 their original size See your DEALER for replacements Galvanic corrosion destroys underwater metal parts and can occur in fresh or salt water however salt brackish and polluted waters will accelerate corrosion Metal based antifouling paint on the boat or motor and the use of improperly installed shore power in the area of your moored boat will also accelerate corrosion IMPORTANT NEVER paint the a...

Page 42: ...erating lights on a boat An AC lighting system is available as an optional kit IMPORTANT Alternating current is generated and MUST NOT be connected directly to a battery For battery charging install a battery charging kit See your DEALER Various combinations of light bulbs can be used Use 12 volt bulbs of wattage sizes indicated on the diagram Follow the illustration for proper installation of wir...

Page 43: ...ure Engine will not idle properly Motor angle excessive Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel system contaminated with water or dirt Carburetor mixture out of adjustment Fuel oil mixture incorrect Engine loses power Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel filter obstructed Fuel system contaminated with water or dirt Water intakes obstru...

Page 44: ... shaft lubricate 1 7 Every 60 days Every 30 in Saltwater Swivel bracket tilt support bracket lubricate 1 7 Every 60 days Every 30 in Saltwater Shift lever shaft and detent shallow water drive bracket inspect and lubricate 1 7 Every 60 days Every 30 in Saltwater Engine cover latch lubricate 1 7 Every 60 days Every 30 in Saltwater Throttle and shift linkage lubricate 1 7 Every 60 days Every 30 in Sa...

Page 45: ...veshaft splines inspect and lubricate 8 D Water pump inspect and replace D 1 Also recommended at 10 Hour Inspection 2 Emission related component 3 Do not use light duty penetrating lubricants D Dealer Performed Service O Operator Performed Service 4 Evinrude Johnson anti corrosion spray or Evinrude Johnson 6 in 1 multi purpose lubricant 5 Ultra HPF gearcase lubricant 6 Power Trim Tilt Fluid 7 Trip...

Page 46: ...44 Maintenance NOTES ...

Page 47: ...Maintenance 45 ...

Page 48: ...g can cause loss of control Contact your DEALER or the boat s manufacturer if your boat lacks a capacity plate Boats designed for remote steered engines might be overpowered by a tiller steered engine of the maximum rated horsepower Ask your DEALER or boat manufacturer is you are unsure about your boat s suitability Incorrectly matched boat and engine tran som heights can cause boat instability an...

Page 49: ... over revving propeller Propeller ventilation slip page often occurs resulting in poor boat perfor mance On a specialty hull non planing hull or on a boat with a curved transom these guidelines might not apply See your DEALER for special installation in formation Installing the Engine IMPORTANT Follow all directions carefully The engine s warranty will not cover product damage or failure that resu...

Page 50: ...y behind the heads and to the shanks of the mounting bolts be fore inserting them and to the surfaces of washers that contact the transom Avoid RTV silicone and polyurethane sealants as they can be dissolved by gasoline Secure the engine with the mounting hardware After 30 minutes of operation retighten clamp screws by hand DO NOT use tools to tighten clamp screws Check clamp screws regularly Conn...

Page 51: ...sition to contact you if correction to your outboard becomes necessary Outside the U S and Canada this card should be sent to the Bombardier division where the outboard was registered Please contact your Dealer or Distributor 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 S...

Page 52: ......

Page 53: ...me 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 Op...

Page 54: ...52 Maintenance ...

Page 55: ...dations in this Guide and take a boating safety course before you operate your boat and motor 6 Do you know who to ask if you have any questions about your boat and motor 7 Do you know your local marine traffic laws 8 Do you understand that human error can be caused by carelessness fatigue overload preoccupa tion unfamiliarity of operator with the product drugs and alcohol just to name a few WARNI...

Page 56: ... 215483 ...