Related Manuals for Johnson 2 Stroke 40 HORSEPOWER
Summary of Contents for Johnson 2 Stroke 40 HORSEPOWER
- Page 1 2005 2 Stroke 40 HORSEPOWER R, RL 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.
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Page 3: Table Of Contents
SAFETY — THE RIGHT PLACE TO GET STARTED ....................2 PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ..............4 BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON 2-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ........5 BOMBARDIER MOTOR CORPORATION OF AMERICA 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 It can be worsened or caused by weather, For more information, see your Evinrude/ mooring and operating conditions, and other Johnson Dealer for a copy of Introduction to boats. Avoid exhaust fumes from your engine High Performance Boating, P/N 335763.
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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 ar- nearest Evinrude/Johnson Dealer in the United eas. States and Canada log on to www.evinrude.com or www.johnson.com. -
Page 7: Bombardier Motor Corporation Of America Limited Warranty For 2005 Johnson 2-Stroke Outboard Engines Sold In The United States And Canada
This warranty coverage is available only on Johnson 2-stroke outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred ("Dealer"), and then only after the BMCA specified pre-delivery inspection process has been completed and documented by the purchaser and Dealer. - Page 8 5. WHAT BOMBARDIER MOTOR CORPORATION OF AMERICA WILL DO Bombardier 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 the reasonable judgment of BMCA.
- 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...
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Page 10: Bombardier Motor Corporation Of America 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 Motor Corporation of America (“BMCA”) distrib- utor/dealer authorized to distribute Johnson 2-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 Product was registered for warranty. - Page 11 NOTES General Information -...
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Page 12: Features
FEATURES 000101 Item Description Item Description AC Lighting Inlet Clip and Lanyard Assembly Water Pump Indicator Steering Handle and Twist-Grip Throttle Tilt/Run Lever Idle Speed Adjustment Knob Angle Adjusting Rod Stop Button/Emergency Stop Switch Anticorrosion Anode Primer Knob Lubricant Drain/Fill Plug Shift Lever Lubricant Level Plug Starter Handle... - Page 13 000102 Item Description Item Description Installation Hardware Trim Tab Fuel Connector ECI Label Emergency Restart Clip Storage Engine Cover Latch Tilt Support Bracket Spark Plugs Steering Friction Adjustment Screw Water Pressure Tap Model and Serial Number Plate Lifting Eye Water Intakes Fuel Pump Filter Propeller Emergency Start Cord...
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Page 14: Engine Specifications
18 to 21 ft. lbs. (24 to 28 N · AC Lighting 60 watts AC @ 12 volts Gearcase –Lubricant Evinrude/Johnson Ultra-HPF™ gearcase lubricant Capacity 16.4 fl. oz. (485 ml) Propeller 12 1/4 x 15 in. (311 x 381 mm) Fuel Tank Capacity –... -
Page 15: Emergency Stop Switch
EMERGENCY STOP SWITCH An extra clip is provided — another person can in- sert it in the stop switch and start the motor in an emergency. If equipped, the emergency stop switch is on the steering handle. Use of the emergency stop feature is highly recommended on all boats. -
Page 16: 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 17: Additives
BMCA for your outboard. Use of other fuel additives oil. 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. It can be used continuously and should be used during any period when your engine is not being operated on a regular basis. -
Page 18: Fuel Systems
FUEL SYSTEMS IMPORTANT: Before the first start-up of your new engine: • Read Engine Starting, Engine Stopping, and Shifting and Speed Control. WARNING • Check the gearcase lube level. Refer to Lubrica- tion. If your motor is equipped with a quick-dis- •... -
Page 19: Engine Starting
ENGINE STARTING BEFORE START-UP DANGER Review and follow Break-In (10 Hours) if the en- gine is new. DO NOT run the engine indoors or without adequate ventilation or permit exhaust You MUST supply water to the engine before at- fumes to accumulate in confined areas. tempting to start it. - Page 20 If equipped, open vent screw on fuel tank’s filler cap. WARNING Squeeze fuel primer bulb, outlet end up, until firm. Always shift to NEUTRAL before starting the engine to prevent sudden boat move- ment, which can cause injury. Twist the throttle grip to START. 1.
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Page 21: Engine Stopping
The manual primer has two functions. It primes the Start-up (Warm Engine) engine for quick cold starting and provides extra Follow Cold Engine procedure except warm en- fuel for warm-up. Push primer in to RUN (no color gines do not normally require priming. If your en- line showing) when motor is sufficiently warmed up. -
Page 22: 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; or 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 23: Fuel Economy
Be sure: • Tilt/run lever is in the RUN position • Engine is in normal operating position. • Fuel hose primer bulb is firm. • Shift lever is in NEUTRAL. • Twist-Grip throttle is at START. Remove engine cover. 1. Starter handle bracket screws Hook the knot of your emergency start cord into the notch on the flywheel. -
Page 24: Operation
OPERATION Operation Underway DANGER The Touch-Trim feature allows the operator to trim the motor (change motor angle) while underway to improve acceleration, speed, and to meet changing DO NOT run the engine indoors or without water conditions. adequate ventilation or permit exhaust fumes to accumulate in confined areas. - Page 25 You can now resume operation in a manner suit- Bow-Down able for the new trim position. To move the boat’s bow DOWN: IMPORTANT: DO NOT operate the motor if the wa- • Make sure the engine is at a constant throttle set- ter intakes are not completely submerged.
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Page 26: Trailering
TRAILERING Grasp tilt grip on engine cover and tilt or lower mo- tor to any position desired. 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 the tilt support or an accessory trailering bracket. -
Page 27: Tilt Support
TILT SUPPORT MOTOR ANGLE ADJUSTMENT Motor should be perpendicular to the water when Engage the boat is underway at full speed. This adjustment Raise the motor to full TILT position. Refer to Tilt- can only be determined by water testing the boat. ing. -
Page 28: Propeller Selection
PROPELLER SELECTION Outboard — Running To select the correct propeller for your boating ap- WARNING plication, your boat and motor MUST be water test- ed. See your Dealer for assistance. Prevent injury from contact with rotating Refer to Propeller, before removing or installing propeller;... -
Page 29: Engine Overheating
ENGINE OVERHEATING IF the S.L.O.W. protection system activates and the stream from the water pump indicator becomes in- termittent or stops, reduce speed to idle and: IMPORTANT: Do not run your engine — even for a • Shift to NEUTRAL; brief start-up —... -
Page 30: Impact Damage
IMPACT DAMAGE Your engine has a shock absorption system de- signed to help withstand damage from impact with underwater objects at low to moderate speeds. However, high speed impacts with rigid underwater objects like pilings or boulders can be beyond the capability of the absorption system. -
Page 31: Special Operating Conditions
After operating your outboard, rinse it with fresh wa- After submersion, all boat and engine electrical, fu- ter and wipe it dry. Apply Evinrude/Johnson anti- el, and oiling systems must be inspected for signs corrosion spray to any surface subject to corrosion, of water intrusion. -
Page 32: Maintenance
MAINTENANCE OFF-SEASON STORAGE Maintenance, replacement, or repair of the 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 33: Pre-Season Service
Examine all loosened or removed hardware and Fuel filter — Clean. any steering, throttle, and shift systems. Replace damaged or missing parts with Evinrude/Johnson Screws, bolts, nuts — Tighten that Genuine Parts or equivalent. loose. -
Page 34: Adjustments
ADJUSTMENTS Steering Friction The steering friction was set on your new motor be- fore it left the factory. After the first 10 hours of ser- Idle Speed vice, check to see that it is still correct. A slight drag The idle speed adjusting knob is located at the end should be felt when turning the motor. -
Page 35: Lubrication
With the motor shut OFF, loosen the trim tab IMPORTANT: The recommended gear lubricants screw. If the boat pulled to the right, move the rear include special additives for marine applications. of the trim tab slightly to the right. If the boat pulled Do not use automotive gear lubricants, 2-stroke or to the left, move the rear of the trim tab slightly to 4-stroke engine oil, or any other oil or grease for... - Page 36 Lubrication Points Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom- mended lubricant. 1. Control shaft bushings, control lever bearings, carburetor linkage, roller (cam follower) 1. Swivel bracket and tilt support 1. Throttle cable bushings 2. Spark advance linkage 1.
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Page 37: Water Pressure
FUEL PUMP FILTER Check for leaks – connect fuel hose to motor and squeeze primer bulb until firm. The fuel filter is located in the motor’s fuel pump. An authorized Evinrude/Johnson Dealer should ser- vice the fuel filter. WARNING WARNING... -
Page 38: Spark Plugs
SPARK PLUGS PROPELLER WARNING WARNING The ignition system presents a serious When servicing the propeller, twist and shock hazard. The primary circuit operates remove all spark plug leads so the engine in excess of 250 volts; the secondary circuit cannot be started accidentally. operates in excess of 25,000 volts. -
Page 39: Anticorrosion Anodes
Continue to tighten propeller nut until nut slots and ANTICORROSION ANODES cotter pin hole are aligned. Install new cotter pin and bend ends to secure. Your motor is equipped with one or more anodes that protect it from galvanic corrosion. Refer to Fea- tures for anode location. -
Page 40: 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 hose disconnected, kinked. •... -
Page 41: 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 42 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 Molylube P/N 175356 Evinrude/Johnson Engine Tuner...
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Page 43: Installation
INSTALLATION Transom Height and Shaft Length The transom height dimension listed in Engine Specifications is the height of the boat transom WARNING your engine needs. This dimension is measured at the transom centerline, perpendicular to the bottom of the boat. Your engine must not exceed the maximum horsepower indicated on the boat’s capacity plate. - Page 44 Adjust the motor angle so the antiventilation plate is Installing the Engine parallel with the boat bottom. Refer to Motor Angle Adjustment. WARNING The resulting position of the antiventilation plate must be no higher than the boat’s bottom and no The outboard must be correctly installed.
- Page 45 Loosen clamp screws and apply caulk on and around bolts between stern brackets and transom to keep water out of the drilled holes. WARNING When replacing bolts, screws, or other fas- teners, use Johnson parts or parts of equiv- alent strength and material. Maintenance -...
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Page 46: Ac Lighting
AC LIGHTING 1. Sleeve 2. Electrical tape covering connection 3. Light bulb Y – Yellow wire YG – Yellow/Grey wire YB – Yellow/Blue wire Some models have an AC (alternating current) lighting system for operating lights on a boat. An AC lighting system is available as an optional kit. - 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 BMCA will be in a position to contact you if correction to your outboard becomes necessary.
- Page 48 B o m b a r d i e r M o t o r C o r p o r a t i o n o f A m e r i c a - Maintenance...
- Page 49 Bombardier Recreational Products Maintenance -...
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Page 50: 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 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.
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