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• Page 1
  2005 4 Stroke 4/5/6 HORSEPOWER R4, RL4 WARNING Read this Operator Guide thoroughly. It contains important safety information. When operating your boat, always have this Operator Guide onboard.
• Page 2
  An Operator’s Readiness Test has been prepared on the last page of this Guide. Be safe! All passengers should be familiar with the proper operation of your boat and Johnson outboard. Be certain they fully understand and respect the controls and operation. Each operator is responsible for the safety of all passengers and other boaters.

• Page 3: Table Of Contents

  SAFETY — THE RIGHT PLACE TO GET STARTED ………………..2 PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS …………..4 BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ………………..5 BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ……………….

• Page 4: General Information

  1-800-336-BOAT. For equipment. It will acquaint the operator and pas- additional information about boating safety and reg- sengers with the Evinrude/Johnson outboard and ulations call: U.S. Coast Guard Boating Safety Hot- its controls, operation, maintenance and boating line 1-800-368-5647.

• Page 5
  For more information, see your Evinrude/ and operating conditions, and other boats. Johnson Dealer for a copy of Introduction to Avoid exhaust fumes from your engine or oth- High Performance Boating, P/N 335763. er boats, provide proper ventilation, shut off your engine when not needed, and be aware SAFETY MEASURES —…

• Page 6: Product References, Illustrations And Specifications

  Certain features of systems discussed in this Guide from your selling Dealer. For the name and location might not be found on all models in all marketing ar- of the nearest Evinrude/Johnson Dealer in the Unit- eas. ed States and Canada visit www.evinrude.com or www.johnson.com.

• Page 7: Brp Us Inc. Limited Warranty For 2005 Johnson 4-Stroke Outboard Engines Sold In The United States And Canada

  This warranty coverage is available only on Johnson 4-stroke outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred («Dealer»), and then only after the BRP US Inc. specified pre-delivery inspection process has been com- pleted and documented by the purchaser and Dealer.

• Page 8
  4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect. Owner must bring Product, including any defective part therein, to Dealer promptly after the appearance of the defect, and in any event, within the warranty period, and must provide Dealer with reasonable op- portunity to repair the defect.
• Page 9
  7. LIMITATIONS OF LIABILITY ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN- TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA- TION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY. ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expense for transporting Product to and from Dealer, removal of Product from a boat and reinstallation, mechanic’s travel time, in-and-out of water charges, slip or dock fees, trailering or…

• Page 10: Brp Us Inc. Limited Warranty For 2005 Johnson 4-Stroke Outboard Engines Sold Outside The United States And Canada

  For a copy of the Limited Warranty, see your BRP US Inc. distributor/dealer authorized to distribute Johnson 4-Stroke products in the country in which the sale occurs. If further assistance is required, please contact BRP US Inc. Customer Support Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of Bombardier Recreational Products Inc.

• Page 11: California Emission Control Warranty Statement

  CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your Johnson 4-stroke outboard has a special environmental label required by the California Air Resourc- es Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard, describes the meaning of the star rating system.

• Page 12
  Johnson 4-stroke outboards are still applicable to these models with the necessary modifications. Select emission control parts of your Johnson 4-stroke outboard are warranted from the date of purchase by the first retail consumer or the date the product is first put to use, whichever occurs first, for a period of: 4 years, or for 250 hours of use, whichever occurs first.
• Page 13
  For any questions regarding your warranty rights and responsibilities or for the name and location of the nearest authorized BRP US Inc. dealer, contact BRP US Inc. Customer Support Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.johnson.com. General Information -…

• Page 14: Features

  FEATURES Item Description Item Description Motor Cover Lubricant Level Plug Tilt Grip Clamp Bracket Rear Handle Clamp Screw Water Pump Indicator / Flushing Port Emergency Stop Switch / STOP Button & Lanyard Steering Friction Throttle Friction Tilt Lock Lever Throttle Grip Angle Adjustment Rod Fuel Connector Anti-Corrosion Anodes…

• Page 15
  Item Description Item Description Choke Knob Spark Plug Oil Inspection Window Starter Grip Fuel Shut Off Valve Engine Cover Bumpers Fuel Tank Emergency Starter Cord Tool Kit (1) Not supplied in all marketing areas. General Information -…

• Page 16: Engine Specifications

  SAE J1930 Fuel Requirements 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil Crankcase – Oil Evinrude®/Johnson® Ultra ™ 4-Stroke synthetic blend oil – Refer to Fuel and Oil Capacity 23.7 fl. oz. (0.7 Liter) Filter…

• Page 17: Emergency Stop Switch

  EMERGENCY STOP SWITCH An extra clip is provided on the emergency stop lan- yard — another person can insert it in the stop switch and start the motor in an emergency. If equipped, the emergency stop switch is on the steering handle.

• Page 18: Fuel And Oil

  FUEL AND OIL FUEL Minimum Octane Inside the U.S. 87 (R+M)/2 AKI WARNING Outside the U.S. 91 RON Gasoline is extremely flammable and highly Your outboard has been designed to operate using explosive under certain conditions. Follow the above fuels; however, be aware of the follow- the instructions in this section explicitly.

• Page 19: Oil

  It allows for extended oil change intervals and If your motor is equipped with a quick-dis- is best for high load applications. Evinrude/Johnson connect fuel hose, disconnect the fuel hose Ultra 4-Stroke synthetic blend oil delivers ultra vis-…

• Page 20: Break-In (10 Hours)

  Find and correct the first time. It is recommended you add Evinrude/ cause, or see your Dealer before you continue. Johnson 4-Stroke outboard oil. Refer to Changing • Verify shift function by shifting into gear and ob- the Oil for acceptable substitute lubricants.

• Page 21: Engine Starting

  ENGINE STARTING Built-In Fuel Tank DANGER Open the vent screw on the fuel tank cap. • Clockwise to close. DO NOT run the engine indoors or without • Counterclockwise to open. 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.

• Page 22
  If equipped, open vent screw on fuel tank’s filler All Models cap. If equipped, attach the clip and lanyard assembly to Squeeze fuel primer bulb, outlet end up, until firm. the emergency stop switch / STOP button. Snap the lanyard to secure place on your clothing or life vest.

• Page 23: Engine Stopping

  While seated, grasp the starter handle and pull ENGINE STOPPING slowly until the starter engages, then pull hard. Al- low the starter cord to rewind slowly. Twist the throttle grip to IDLE position or slower. If your engine doesn’t start after three pull, push the choke knob in and repeat the starting procedure.

• Page 24: Shifting And Speed Control

  SHIFTING AND SPEED CONTROL Speed Control With the engine running, twist the throttle grip: IMPORTANT: Carefully check the function of all • Counterclockwise to increase speed control and engine systems before leaving the • Clockwise to decrease speed dock. DO NOT shift the engine into FORWARD or REVERSE while it is shut OFF.

• Page 25
  Move the shift lever to NEUTRAL. Loosen the lock nut, take off the NSI cable from the bracket, and separate the end of the cable from the cam. 1. NEUTRAL Remove the engine cover. 1. Lock nut 2. Cam Lift off the recoil starter assembly. Tie a knot in one end of the emergency starter cord.

• Page 26: Operation

  OPERATION DANGER WARNING DO NOT run the engine indoors or without DO NOT place your hands near the mount- adequate ventilation or permit exhaust ing bracket or under the motor when tilting, fumes to accumulate in confined areas. or they could be crushed if the motor slips Engine exhaust contains carbon monoxide from your grasp.

• Page 27: Shallow-Water Drive

  Tilt Down WARNING Grasp tilt grip on engine cover and raise motor slightly. Pull up on the tilt lock lever. Slowly lower motor to its normal operating position. When using the shallow-water drive bracket, the tilt lock feature will not work. Operate your motor in FORWARD and ONLY at slow speed.

• Page 28: Flushing

  FLUSHING Outboard — Running 1) Place the engine in vertical position in a well- ventilated area with good drainage. DANGER 2) Remove the plug from the flushing port. 3) Install flushing device and garden hose. 4) Cover the water intake hole with tape. DO NOT run the engine indoors or without 5) Place the shift lever in NEUTRAL with the adequate ventilation or permit exhaust…

• Page 29: Engine Overheating

  ENGINE OVERHEATING If the stream from the water pump indicator be- comes intermittent or stops, reduce speed to idle and: IMPORTANT: Do not run your engine — even for a Shift to NEUTRAL; brief start-up — without supplying water to it. Refer to Flushing.

• Page 30: Trailering

  TRAILERING Trailer your boat with the motor in a vertical posi- tion. If your trailer does not provide adequate road clearance, the motor can be trailered by using an accessory trailering bracket. See your Dealer. DO NOT use the tilt lock lever when trailering. IMPORTANT: Whenever using an accessory traile- ring bracket, the motor must be restrained.

• Page 31: Storing

  STORING Horizontal transport Drain the gasoline from the carburetor. If you must tilt the motor to remove it from the water, Raise the tiller handle and rest it on a padded sur- lower it and allow the cooling system to drain com- face on its port side.

• Page 32: Special Operating Conditions

  After operating your outboard, rinse it with fresh wa- el, and oiling systems must be inspected for signs ter and wipe it dry. Apply Evinrude®/Johnson® anti- of water intrusion. Your Dealer should perform this corrosion spray to any surface subject to corrosion, service.

• Page 33: Maintenance

  Maintenance, replacement, or repair of the EPA Emission Regulations emission control devices and systems may be All new 2002 and more recent Johnson outboards performed by any marine SI (spark ignition) en- manufactured by BRP US Inc. are certified to the gine repair establishments or individual.

• Page 34: 10-Hour Inspection

  Stop the engine and drain the crankcase while the Your Dealer will perform this 10-Hour Inspection at engine is warm. Refill it with Evinrude/Johnson Ul- your request and expense (based on local rates), tra 4-Stroke synthetic blend oil. Refer to Crankcase according to what your engine needs —…

• Page 35: Pre-Season Service

  OFF the engine Replace damaged or missing parts with Evinrude/ and disconnect the flusher. Refer to Flushing. Johnson Genuine Parts , or equivalent. Refer to Propeller to install the propeller. Portable fuel tank — Disconnect the hose from the tank.

• Page 36: Crankcase Oil

  It is recommended you add Evinrude/ If Evinrude/Johnson Ultra 4-Stroke synthetic blend Johnson 4-Stroke outboard oil. Refer to Changing oil is temporarily unavailable, you may use the Oil for acceptable substitute lubricants.

• Page 37: Adjustments

  3) Fully steer the outboard to the starboard side. ADJUSTMENTS 4) Hold a suitable container under the oil drain screw. Remove the screw and drain the re- Throttle Friction servior. Before you reinstall the screw, re- place the gasket with a new one. Reinstall the Adjust until a slight drag is felt when accelerating or screw and tighten it securely.

• Page 38: Lubrication

  LUBRICATION 3) Place tube of lubricant in drain/fill hole and fill slowly until lubricant appears at lubricant lev- el hole. See Engine Specifications for gear- Gearcase case capacity. 4) Install lubricant level plug before removing Replace gearcase lubricant after first 10 hours of tube from drain/fill hole.

• Page 39
  Lubrication Points Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom- mended lubricant. 1. Clamp screws 1. Throttle linkage 1. Swivel bracket 1. Shift lever 2. Steering bracket 1. Propeller shaft Maintenance -…

• Page 40: Breather And Fuel Line

  BREATHER AND FUEL LINE SPARK PLUGS Inspect the breather and fuel line for leaks, cracks, swelling, or other damage. If the breather and fuel WARNING line are damaged in any way, they must be re- placed. See your Dealer. The ignition system presents a serious shock hazard.

• Page 41: Propeller

  PROPELLER Repair If your propeller hits a solid object, the impact is par- tially absorbed by the rubber bushing in the hub to help prevent damage to the engine. A strong impact WARNING can damage the hub and propeller blades. Damage to blades can cause unusual and excessive vibra- To avoid accidental starting of engine while tion.

• Page 42: Trouble Check Chart

  TROUBLE CHECK CHART IMPORTANT: If you are unable to identify or solve the problem, contact your Dealer. SYMPTOM POSSIBLE CAUSE Engine will not start • Not following starting instructions. Refer to Engine Starting Sec- tion. • Fuel tank empty. • Fuel hose disconnected, kinked. •…

• Page 43: Engine Maintenance And Inspection Schedule

  ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following maintenance chart provides guidelines for engine maintenance and in- spection scheduled to be performed by you and/or by an authorized Dealer. The schedule should be ad- justed according to operating conditions and use.

• Page 44
  Ignition timing, check (1) Also recommended at 10-Hour Inspection (2) Emission-related component Dealer Performed Service Operator Performed Service Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1” multi-purpose lubricant Ultra-HPF gearcase lubricant Power Trim/Tilt Fluid Triple-Guard grease Evinrude/Johnson Molylube P/N 175356…

• Page 45: Installation

  INSTALLATION TRANSOM HEIGHT AND SHAFT WARNING LENGTH Your engine must not exceed the maximum The transom height dimension listed in Engine horsepower indicated on the boat’s capacity Specifications, is the height of the boat transom plate. Such overpowering can cause loss of your engine needs.

• Page 46: Installing The Engine

  WARNING INSTALLING THE ENGINE When replacing bolts, screws, and other fasteners, use Evinrude/Johnson Genuine Parts or parts of equivalent strength and Center the engine on the boat’s transom (or mount- material. ing bracket) and tighten the clamp screws by hand, NOT with tools.

• Page 47
  CHANGE OF ADDRESS / CHANGE OF OWNERSHIP If your address has changed or if there has been a change of ownership, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since BRP US Inc.
• Page 48
  B R P U S I n c . E v i n r u d e J o h n s o n D e a l e r S u p p o r t S e r v i c e s 2 5 0 S e a h o r s e D r i v e W a u k e g a n , I L 6 0 0 8 5 — Installation…

• Page 49: Confirmation Of Receipt

  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.

• Page 50
  BRP US Inc. — Installation…
• Page 51
  Readiness Test and a Final Word to the Owner/Operator The Operator’s Readiness Test..1. Did you read this Guide from front cover to rear cover? 2. Are you ready to take responsibility for the safe operation of your boat and motor? 3.
• Page 52
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