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Johnson R Operator's Manual

3.5 horsepower 2-stroke
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  • Page 2 An Operator’s Readiness Test has been prepared on the last page of this manual. 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 LIMITED WARRANTY FOR 2006 JOHNSON 2-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ....................5 BRP LIMITED WARRANTY FOR 2005 JOHNSON 2-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 selling Dealer. For the name and location of the might not be found on all models in all marketing nearest Evinrude/Johnson Dealer in the United areas. States and Canada log on to www.evinrude.com or www.johnson.com.

  • Page 7: Brp Limited Warranty For 2006 Johnson 2-Stroke Outboard Engines Sold In The United States And Canada

    Bombardier Recreational Products Inc. ("BRP") warrants its 2006 Johnson ® 2-stroke outboard engines sold by authorized Johnson dealers in the fifty United States and Canada ("Product") from defects in ma- terial or workmanship for the period and under the conditions described below. 2. WARRANTY COVERAGE PERIOD...
  • Page 8 5. WHAT BRP WILL DO BRP's obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts of Product found to be defective in material or workmanship, in the reasonable judgment of BRP. Such repair or replacement of parts will be done without charge for parts and labor, at any authorized Dealer. BRP's responsibility is limited to making the required repairs or replacements of parts with new or BRP-certified re-manufactured parts.
  • 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 Limited Warranty For 2005 Johnson 2-Stroke Outboard Engines Sold Outside The United States And Canada

    For a copy of the Limited Warranty, see your Bombardier Recreational Products Inc. (“BRP”) distributor/ dealer authorized to distribute Johnson 2-stroke products in the country in which the sale occurs. If further assistance is required, please contact BRP Customer Support Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BRP where the Product was registered for warranty.
  • Page 11 General Information -...

  • Page 12: Features

    FEATURES 000128 Item Description Item Description Fuel Filter Clamp Screws Engine Cover Latch Model and Serial Number Plate Fuel Shut-Off Carrying Handle Shift Lever Throttle Control Lever Tilt Lock Pin Choke Knob Lubricant Level Plug Stop Button Water Intake Starter Handle Lubricant Drain/Fill Plug - General Information...
  • Page 13 000129 Item Description Item Description Steering Handle Water Pump Indicator Tilt Friction Nut Spark Plug Angle Adjustment Bolt Tilt Grip Anticorrosion Anode Fuel Tank Cap Drive Pin Fuel Tank Vent ECI Label Propeller Steering Friction Adjustment Screw General Information -...

  • Page 14: Engine Specifications

    Spark Plug Refer to ECI Label Torque 18 to 21 ft. lbs. (24 to 28 N·m) Gearcase – Lubricant Evinrude/Johnson Ultra-HPF™ gearcase lubricant Capacity 2.7 fl. oz. (80 ml) Propeller 7 1/2 x 6 in. (191 x 152 mm) Transom Height 14 1/2 to 15 in.

  • Page 15: Fuel And Oil

    If Evinrude/Johnson XD25 formula outboard oil is not available, you must use an NMMA-certified TC- W3 oil such as Evinrude/Johnson direct injection oil or Evinrude biodegradable outboard oil. IMPORTANT: Failure to follow this recommenda- tion could void the engine warranty if a lubrication- related failure occurs.

  • Page 16: Additives

    BRP for your outboard. Use of other fuel additives can result in poor performance or engine damage. Evinrude/Johnson 2+4 fuel conditioner will help prevent gum and varnish deposits from forming in fuel system components, and will remove moisture from the fuel system.

  • Page 17: Break-In

    BREAK-IN Launch the boat and start the engine according to the procedures in Engine Starting. IMPORTANT: Follow this procedure to protect your Verify water pump operation often. Look for a new outboard during its initial hours of operation. steady stream of water from the water pump indica- Careful break-in allows internal engine components tor.

  • Page 18: Engine Starting

    ENGINE STARTING Open the fuel shut-off by turning the valve knob so its handle is vertical. 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.

  • Page 19: Engine Stopping

    ENGINE STOPPING While seated, grasp the starter handle and pull slowly until starter engages, then pull hard. Allow starter cord to rewind before releasing the handle to Press the stop button until the engine stops run- prevent damage to starter. ning.

  • Page 20: Shifting And Speed Control

    SHIFTING AND SPEED CONTROL WARNING IMPORTANT: Carefully check the function of all control and engine systems before leaving the Remember when the engine is in REVERSE dock. If the following directions are not suitable for position, the throttle lever and the stop but- your boat’s control, see your Dealer before pro- ton are facing away from the operator.

  • Page 21: Emergency Starting

    EMERGENCY STARTING Tie a knot in the end of your emergency starter cord and hook it in the notch on the flywheel. Wind the cord clockwise around the starter ridge on the fly- wheel. WARNING The engine cover is a machinery guard. Pre- vent injury by keeping hands, clothing and hair clear of all moving parts.

  • Page 22: Operation

    OPERATION TILTING DANGER To tilt the motor, grasp tilt grip at rear of engine cov- er and pull motor to full tilt position. Push in the tilt DO NOT run the engine indoors or without lock pin. adequate ventilation or permit exhaust fumes to accumulate in confined areas.

  • Page 23: Motor Angle Adjustment

    MOTOR ANGLE ADJUSTMENT Tighten the wing nut and replace the thread sleeve. The engine should be perpendicular to the water when the boat is underway at full speed. This ad- justment can only be determined by water testing the boat. Set angle adjustment for your normal load.

  • Page 24: Carrying And Transporting

    CARRYING AND TRANSPORTING FLUSHING Before you shut the engine off for the last time dur- ing your outing, close the fuel shut-off valve and the DANGER fuel tank vent screw. Run the engine until it quits. Doing so will minimize the potential for fuel leakage DO NOT run the engine indoors or without when you lay the engine down.

  • Page 25: Engine Overheating

    ENGINE OVERHEATING IMPORTANT: Do not run your engine — even for a brief start-up — without supplying water to it. Refer to Flushing. While boating, the engine’s water intakes must stay completely submerged and unobstructed. Observe proper transom height and trim angle. While the en- gine is running, the engine’s water pump indicator must discharge a steady stream of water.

  • Page 26: Trailering

    TRAILERING WARNING Keep everyone clear of stern area when raising or lowering the outboard. Personal injury or death can result from contact with moving parts of the outboard. Trailer your boat with the motor in a vertical posi- tion. If your trailer does not provide adequate road clearance, gain additional clearance by placing the angle adjustment rod in the hole furthest out.

  • Page 27: Special Operating Conditions

    After operating your outboard, rinse it with fresh wa- • Tilt its gearcase out of the water; and ter and wipe it dry. Apply Evinrude/Johnson Anti- • Off-load all persons into another boat. Corrosion Spray to any surface subject to corro- sion, but avoid the anticorrosion anode(s).

  • Page 28: Maintenance

    MAINTENANCE Maintenance, replacement, or repair of the OFF-SEASON STORAGE emission control devices and systems may be performed by any marine SI (spark ignition) en- You must protect against natural environmental gine repair establishments or individual. conditions that can be damaging to an outboard motor.

  • Page 29: Pre-Season Service

    Examine all loosened or removed hardware and any steering, throttle, and shift systems. Replace damaged or missing parts with Evinrude/Johnson Genuine Parts or equivalent. Stop the engine by closing the fuel shut-off valve WARNING and letting the engine run the carburetor out of fuel.

  • Page 30: Adjustments

    Carburetor Follow Engine Starting and start the engine. Let it idle while you: High speed fuel calibration is maintained by fixed Observe running quality. If poor, refer to Trouble high speed jet in the carburetor. Fixed jets are not Check Chart or see your Dealer. adjustable.

  • Page 31: Lubrication

    LUBRICATION Lubrication Points Refer to Engine Maintenance and Inspection Gearcase Schedule for lubrication frequency and recom- mended lubricant. Replace gearcase lubricant after first 10 hours of operation. Check level and condition of lubricant af- ter next 50 hours of operation. Add lubricant if nec- essary.

  • Page 32: Fuel Filter

    FUEL FILTER Refer to Engine Maintenance and Inspection Schedule for frequency. An authorized Evinrude/Johnson Dealer should service the fuel filter. IMPORTANT: A restricted fuel delivery system will not allow the engine fuel pump to deliver sufficient fuel under all conditions.

  • Page 33: Propeller

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

  • Page 34: 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. • Fuel tank empty. • Fuel system contaminated with water or dirt. •...
  • Page 35 NOTES Maintenance -...

  • Page 36: 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 37 Water pump, inspect and replace (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 Triple Guard grease Evinrude/Johnson Engine Tuner Maintenance -...

  • Page 38: Installation

    INSTALLATION Use this procedure to determine whether or not the boat’s transom height is correct for the engine’s shaft length: WARNING Lift the engine using the lift grips (NOT the tilt grip or steering handle) and place it in the center of the boat’s transom.
  • Page 39 Installing Connect a strong line to the engine and a secure place on the boat. If the engine leaves the boat dur- ing operation, a strong line will keep it from being IMPORTANT: Follow all directions carefully. The lost. engine’s warranty will not cover product damage or failure that results from incorrect engine installation.
  • Page 40 - Maintenance...
  • Page 41 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 will be in a position to contact you if correction to your outboard becomes necessary.
  • Page 42 - Maintenance...
  • Page 43 NOTES Maintenance -...
  • Page 44 Evinrude perfectly with your Evinrude or Johnson outboard. and Johnson engines AND the type of boat you Evinrude and Johnson Genuine Parts and ac- use. It doesn’t matter whether you have an offshore...
  • Page 45 Maintenance -...
  • Page 46 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 Johnson Outboard. I have also received a copy of the Operator’s Guide.
  • Page 47 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.

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